IPG Launches Smart Diagnostics to Boost Packaging Line Performance

SARASOTA, Fla. – February 20, 2026 – Intertape Polymer Group (IPG), a global provider of packaging solutions, today announced the launch of its “Packaging Diagnostics” program, an advanced suite of services designed to optimize packaging line performance for manufacturers worldwide. The new platform integrates a range of digital tools and expert analysis to increase equipment uptime, drive efficiency, and address the dual pressures of cost reduction and sustainability in a rapidly evolving industrial landscape.

As manufacturers grapple with supply chain complexities and the demand for higher throughput, IPG’s announcement signals a strategic push toward data-driven, service-oriented solutions. The program unifies key technologies—including the iTrack™ remote monitoring system, AF2K adhesion testing, and Gear Up stretch wrap analysis—into a single, cohesive offering aimed at transforming reactive maintenance into a predictive and proactive strategy.

A Response to Mounting Industrial Pressures

The launch arrives at a critical time for the manufacturing sector. Companies across industries like e-commerce, food and beverage, and consumer packaged goods face a persistent battle against operational inefficiency. Industry data suggests that the Overall Equipment Effectiveness (OEE) for many packaging lines hovers between 60-70%, indicating a significant amount of untapped production capacity lost to unplanned stops, reduced speed, and quality defects. These challenges are compounded by skilled labor shortages and the increasing complexity of automated systems from various vendors that must work in harmony.

This environment has fueled a surge in demand for automation and smart factory solutions. The global packaging automation market is on a steep growth trajectory, with analysts projecting it will expand to over $120 billion by 2033. IPG’s Packaging Diagnostics program is positioned to capitalize on this trend by providing a holistic solution that goes beyond selling consumables and machinery, instead offering an ecosystem designed to maximize the performance of the entire packaging operation.

An Integrated, Data-Driven Approach

At the core of Packaging Diagnostics is the integration of digital tools with hands-on expertise. Unlike fragmented solutions that address singular issues, IPG’s platform provides a comprehensive health check for the end of a production line. The program’s strength lies in its unified structure, which combines three specialized services.

First, the iTrack™ system provides real-time, remote monitoring for case-sealing equipment. A key differentiator is its reliance on a dedicated, secure cellular network, which allows it to operate independently of a facility’s local Wi-Fi and provides a more stable, secure data stream. A web-accessible dashboard gives operations managers visibility into critical metrics like throughput, belt speed, tape consumption, and machine uptime, while automated alerts flag anomalies for predictive maintenance before they cause costly stoppages.

"It begins with carton closure pressure-sensitive testing to confirm the correct tape selection is currently in use for each application,” said Jason Fisher, VP of Corporate Marketing at IPG. “From there, we leverage advanced analytics through our iTrack system to help customers achieve peak operational efficiency and provide critical supply chain data to optimize the operation."

Second, the AF2K (Adhesion Force to Kraft) testing service addresses the fundamental need for package integrity. This diagnostic measures the bond strength of tape on corrugated boxes, allowing manufacturers to preemptively identify and solve adhesion problems that could lead to product damage during transit. By ensuring the right tape is used for the right substrate under the right conditions, this service helps protect brand reputation and reduce the costs associated with returns and replacements.

Finally, the Gear Up service targets pallet security and material efficiency. IPG experts evaluate end-of-line stretch wrap systems to identify opportunities for “downgauging”—the practice of using thinner, more advanced films that provide equivalent or superior load containment. This analysis not only improves pallet stability but also delivers significant environmental and financial benefits.

Unlocking Tangible Savings and Sustainability Gains

The most compelling case for IPG's new program lies in its direct impact on a company's bottom line and its environmental, social, and governance (ESG) goals. By moving from a reactive to a predictive maintenance model, manufacturers can drastically reduce unplanned downtime, a major source of financial loss. The insights from iTrack allow for scheduled service that minimizes disruption and maximizes productivity.

Furthermore, the Gear Up service offers a clear path to cost reduction and sustainability. The process of downgauging stretch film can reduce material costs by as much as 30% while simultaneously lowering plastic consumption and waste. For large-scale operations, these savings can be substantial, providing a strong return on investment. This focus on material optimization aligns with growing consumer and regulatory pressure on companies to reduce their environmental footprint.

Combined with AF2K testing that prevents product loss from failed packaging, the entire suite works to minimize waste across the board. By ensuring packages are sealed correctly the first time and wrapped with optimal material usage, the program reduces rework, material waste, and the carbon emissions associated with shipping replacements for damaged goods.

Reshaping the Competitive Landscape

With the launch of Packaging Diagnostics, IPG is making a significant strategic play to differentiate itself in a crowded market. Competitors like Sealed Air, with its “Precision Yield Optimization,” and Signode, with its “Packaging Plus Reliability Services,” also offer sophisticated data and service solutions. However, IPG is betting on the power of its vertically integrated model, which combines its own tapes, films, and machinery with a service layer designed to optimize them all.

This move positions IPG not merely as a supplier of consumables but as an end-to-end strategic partner invested in its customers' success. By creating this integrated ecosystem, the company aims to foster deeper, more resilient customer relationships that are less susceptible to price-based competition. The platform effectively creates a 'sticky' ecosystem where the performance of IPG’s products is enhanced by its proprietary diagnostic services, creating a powerful value proposition.

This strategy reinforces IPG’s identity as a “fully integrated, vertical supplier” and represents a broader shift in the industrial sector toward service-based revenue models. By providing measurable improvements in efficiency, cost, and sustainability, IPG is aiming to prove that the true value of a packaging solution lies not just in the products themselves, but in the intelligence that governs their performance.