Automation. It’s one of the most talked-about topics in plastics processing today—and one of the most misunderstood.

Visit a conference, walk a tradeshow floor, or scroll through LinkedIn, and you’ll see bold claims that the factory of the future is already here: fully automated, lights-out, with no human operators in sight.

In reality, most smart plastics plants are a careful blend of automation and human expertise, where the goal isn’t to replace people, but to help them work smarter, safer, and more productively.

At Turner Group, we work with manufacturers across injection molding, blow molding, and extrusion—and we hear the same questions and misconceptions again and again. Let’s take a closer look at what today’s automation really looks like—and bust a few persistent myths along the way.

Myth #1: Automation Means Lights-Out Manufacturing

We all love the vision of a factory that runs 24/7 with zero human involvement. But in most plastics processing plants, the goal is not total automation—it’s targeted automation where it makes business sense.

That might mean adding a robotic sprue picker or servo robot to handle repetitive demolding tasks, freeing operators for higher-value work.
It might mean automating material handling, mold temperature monitoring, or inline inspection, reducing scrap and rework.

But lights-out manufacturing? That’s still rare, and not the right target for most shops. The smartest companies focus on incremental wins that pay off fast.

Myth #2: Automation Eliminates Jobs

The opposite is usually true: plants that invest in automation often do so because they are growing and need to free up skilled labor.

In many plastics operations, automation augments human work rather than replacing it. Robots take on dangerous, repetitive, or ergonomically difficult tasks—while humans handle complex setup, troubleshooting, and quality control.

And as automation expands, the need for cross-trained technicians, robot programmers, and process engineers only grows.

Myth #3: You Need to Automate Everything to Compete

You don’t. The smartest processors focus on targeted, modular automation.

• Maybe you start with Dynacon modular conveyors to streamline part flow
• Maybe you add Sepro robots on your busiest injection molding cells.
• Maybe you deploy Smartflow cooling monitoring to tighten mold cooling control and shorten cycles.
• You might incorporate machine vision systems for real-time part inspection and reject handling
• Or introduce automated assembly stations to handle downstream processes like insert placement, welding, or packaging
• Or for new high-volume production you may choose a fully integrated, factory-tested ARBURG turnkey cell—combining injection molding, automation, and quality monitoring—delivered ready to run.

Each step can deliver measurable gains with a handsome ROI.

What Today’s Smart Plants Really Look Like

In the real world, the most successful plastics processors are building flexible, future-ready factories that blend:

• Modular, scalable automation
• Data-driven process monitoring (OPC UA, MES integration, Smartflow, Kistler, ARBURG ALS/ARS options)
• Human expertise at critical points
• Continuous training to upskill teams

The result may not be a lights-out plant. However, it’s a leaner, faster, more competitive operation—one where technology and people work in harmony.

Bottom Line

Automation isn’t all-or-nothing—and it’s not about eliminating jobs. It’s about building smarter processes and giving your team the tools to compete.

At Turner Group, we partner with plastics processors every day to help them move forward—whether that’s adding a robot, optimizing mold cooling, upgrading to Industry 4.0-ready equipment, or building a fully automated cell.