Manufacturing is at a turning point. For operations that depend on high-throughput, precise ingredient handling, the real threat isn’t just finding people to fill open roles — it’s what happens when you can’t. Labor shortages are a long-term risk to productivity, safety, and growth.
As of February 2025, there are roughly 482,000 unfilled manufacturing jobs in the U.S., according to the Bureau of Labor Statistics. While this number reflects pre-pandemic levels — during which a peak of 1.4 million jobs were lost — it still signals imbalance.
To put it in perspective: Even if every unemployed person with manufacturing experience were hired today, there still wouldn’t be enough people to fill the gap.
It’s not just a hiring problem. It’s a talent pipeline problem. In fact, 65% of manufacturers say attracting and retaining workers is their top business challenge, according to a recent survey by the National Association of Manufacturers.
One possible solution? Automation.
Not automation that replaces people, but automated ingredient handling that repositions them into safer, more rewarding roles. Done right, automation turns a labor crisis into an opportunity: to modernize processes using control systems, make jobs more attractive to the next generation, and scale operations sustainably.
Ingredient handling is one of the most physically demanding and high-turnover areas in a production environment. Physically demanding roles, such as lifting 50 pound bags, cause repetitive strain, injury, and are often hard to staff consistently. Bulk ingredient storage systems offer a safer alternative.
The risks go beyond physical. Errors and inefficiencies may happen when unskilled or temporary labor is responsible for feeding machines, manually weighing materials, or managing ingredient flow. Poor dosing, downtime from human error, and ingredient waste are just some of the hidden costs of under-automated ingredient handling systems.
Add in increasing compliance demands — such as dust explosion mitigation and allergen segregation — and it becomes clear: relying on manual labor for core processes is a liability, not a long-term solution.
Modern ingredient handling solutions can take over many of the tasks that are difficult to fill with reliable labor. These include:
Unlike manual processes, automated systems don’t get tired or distracted. They deliver consistent, repeatable results, ensuring your batch always hits spec.
For example, a bulk bag unloader can safely feed a silo or conveyor without operator fatigue or dust exposure from bulk materials, and gravimetric dosing units can ensure every micro-ingredient is added at just the right time and quantity. For the food and pharmaceutical industries, manufacturing control systems are vital to avoid product recalls and validate quality.
One of the top fears of automation is that it will sack your existing workforce. But the only super sacks you want in your production line are bulk bag unloaders! When you realign workers’ roles, you create more appealing and sustainable jobs, particularly to younger workers seeking career growth. It also improves employee health and retention, two key areas where the manufacturing sector has struggled in recent years.
Take the example of a worker who previously spent hours every day dumping and cutting open ingredient bags. With automated ingredient handling systems in place, that person can now become an operations technician, monitoring technology, ensuring bulk materials are flowing correctly, and performing preventative maintenance. It’s a shift from repetitive physical work to skilled technical oversight.
AZO’s automation systems are designed with clear system layout and operator-level controls, making it easier to train current team members and empower them in their new roles. In many cases, operators can be fully trained in system monitoring and control in a small amount of time, depending on the complexity of the system.
Reducing dependency on hard-to-find labor is a benefit in itself, but the ROI of automation goes much further. You’ll get:
Automation also improves compliance with food safety, allergen control, and explosion prevention regulations. For example, NFPA 660 now places responsibility for dust hazard analysis (DHA) on food industry producers, not just equipment suppliers. An automated ingredient handling solution designed with the right explosion vents, dust-tight seals, and filter placements helps ensure a high degree of compliance while protecting workers and facilities.
Across industries, AZO has helped manufacturers transform manual processes with bulk solids and other materials into modern, automated operations:
The manufacturing labor shortage is real. But rather than continuing the costly cycle of hiring, training, and replacing unskilled labor, manufacturers have an opportunity to reimagine their workforce around automation.
With the right systems in place, you can free your people from unsafe tasks and empower them with the expertise to manage high-value processes with precision. Automation of ingredient handling solutions isn't just about machines. It's about building a more resilient workforce and a future-proof business.
Contact AZO to discuss your bulk ingredient automation roadmap.