Episode #11 | The Future of Packaging: Flexibility and Speed in Manufacturing with Jason Head of Fallas Automation

In this episode of Practitioners Unplugged, we dive into the future of secondary packaging automation with Jason Head, Controls Development Engineer at Fallas Automation. Broadcasting from the floor of the Automate Show in Detroit, hosts Dante and Sree sit down with Jason to uncover how Fallas is addressing shifting demands in speed, flexibility, and data-driven design. Fallas Automation builds case packers and secondary packaging systems that sit between primary packaging and end-of-line palletizing — a critical but often overlooked link in the packaging value stream. Jason brings over a decade of hands-on experience in installation, troubleshooting, and now R&D, giving him a front-row seat to how digital transformation is reshaping OEM roles, customer expectations, and machine intelligence. Here are the five key takeaways from our conversation with Jason: 1. Data-Driven Demands Are Reshaping OEM-Customer Dynamics Gone are the days when a machine’s job was to “just run.” Today, end users demand data-rich systems capable of delivering performance metrics, predictive alerts, and operational visibility in real-time. Jason notes a dramatic uptick in customer requests for specific data structures, not just raw data points. Each enterprise seems to have its own “custom standard,” requiring OEMs like Fallas to build tailored data delivery mechanisms. This complexity can slow deployment timelines and increase engineering lift — especially when aligning with proprietary IT/OT frameworks on the customer side. “Each big corporation kind of has their own customized standard that we have to tailor our equipment to… and that definitely holds up getting machines out quickly.” The packaging equipment of tomorrow must be natively data-integrated, not just sensor-ready. 2. Predictive Maintenance Over Scheduled Downtime One of the biggest themes in manufacturing today is reducing unplanned downtime. While predictive maintenance has been a buzzword for years, Jason sees real traction emerging now — particularly in sensor-based component monitoring. Fallas is embedding smarter sensors that help detect part failures before they occur. By moving from scheduled downtime to condition-based maintenance, customers can avoid costly shutdowns and better plan maintenance cycles around actual usage patterns. “We want to incorporate sensors to detect component failures… so our customers can do predictive maintenance instead of run-it-till-it-breaks.” For manufacturers, that means longer machine life, higher uptime, and better OEE across the board. 3. Flexibility at the Operator Level is Critical With turnover rising and skill levels varying widely across facilities, OEMs must build machines that are easy to operate — no matter who’s on shift. Jason emphasizes the importance of designing systems that don’t require robotics expertise or specialized knowledge to run efficiently. “We want to make it where you don’t have to be a robotics expert to package snack foods.” This push toward human-centered HMI design and intuitive machine behavior is a direct response to the transient nature of today’s industrial workforce. The goal is clear: empower operators, reduce the learning curve, and standardize performance regardless of background. 4. Speed is the New Competitive Edge — But It’s Not Easy When one of Fallas’s largest customers asked for a 50% increase in line speed, Jason and his team were forced to rethink everything — from software logic to end-of-arm tooling. Meeting that ask wasn’t just about better hardware; it demanded smarter engineering and faster iteration. “They said, ‘We want to run 50% faster. Can you do it?’ Not only can you do it, but tell us when you’ll be able to deliver it.” The ask was extreme — but not unrealistic. Jason’s team delivered. It required months of planning, iterative tuning on the customer site, and a coordinated effort across upstream and downstream ...