Securing Packaging Operations in a Digitally Connected Environment

As more small and mid-sized packaging companies go digital, they face a new challenge: how to keep systems, data, and products secure in an environment where cyber threats are just as real as physical ones. A 2024 report by IBM found that the average cost of a data breach now exceeds $4.5 million, and manufacturing is one of the most targeted industries. The shift towards cloud-based systems, automated machinery and networked logistics means that even small breaches can disrupt operations, damage trust and trigger regulatory headaches.

So how do packaging companies protect themselves while still embracing digital transformation?

Why Cybersecurity Now Matters in Packaging

In the past, packaging security focused on stopping tampering or spotting counterfeits. Physical barriers, labels, and traceability tools managed most of the risk. Now, as small businesses upgrade to digital workflows and connected machines, cybersecurity is just as important as physical protection.

Modern packaging operations rely on a web of interconnected technologies and every connection is a potential entry point for cyberattacks. Recent trends show that ransomware and supply chain breaches are increasing in frequency and sophistication. Attackers often target smaller, less protected suppliers in order to reach larger manufacturers or retailers. In a packaging context, that could mean compromising design files, altering batch information or interrupting production lines.

The stakes are high. A short production halt caused by a cyber incident can ripple across entire supply chains, especially in food, pharmaceuticals or consumer goods, where delivery timelines are tight and compliance standards are strict.

Common Cyber Threats Facing Packaging

Packaging operations today generate more data than ever before, from design specifications and barcodes to real-time production analytics. This data is valuable, not just for efficiency but also for ensuring traceability and compliance. But when it’s not properly protected, it becomes a liability.

It’s important for any packaging business to know where sensitive information is stored, who can access it, and how it’s shared, whether that’s production data, client details, or payment records. Security frameworks like PCI Data Security Standard provide guidelines that are widely recognized across many industries, not just retail or finance. Key ideas such as encrypting data, limiting access, and monitoring activity can help protect valuable information and keep your business prepared for today’s cyber risks.

We recommend adopting these fundamental practices to strengthen your business’s defenses, simplify compliance, and reassure partners or clients that their information is safe.

For packaging firms, adopting a similar mindset can reduce the risk of breaches and demonstrate accountability to partners and regulators. Even though packaging data may not contain payment information, it often includes client details, intellectual property and proprietary formulations, all of which are prime targets for cybercriminals.

Building Secure Digital Infrastructure for Packaging

When it comes to cyber protection, packaging companies need to think like manufacturers and service providers at the same time. This means balancing physical machinery safety with robust IT protocols.

Key steps include:

Network segmentation (ISA/IEC-62443 style): Use zones and conduits to isolate OT from IT, with an industrial DMZ to prevent a flat network from spreading incidents.
Encryption and authentication: Protecting communications between machines and systems helps prevent unauthorised access or tampering.
Regular patching: Outdated software and firmware are common entry points for attackers. Keeping everything up to date is a simple but effective defence.
Access control: Limiting who can log in, and using multi-factor authentication, reduces risk from compromised credentials.
Continuous monitoring: Detecting unusual activity early helps prevent small issues becoming major disruptions.
Offline backups: Keep tested backups of PLC logic, HMI images, label/serialization masters and MES configs; store a golden copy off the domain.

These measures don’t need to slow down innovation. Many modern OT, MES and traceability platforms ship with built-in security controls that help manage risk without interrupting productivity.

Ensuring Compliance and Protecting Sensitive Data

Technology alone isn’t enough. One of the most common causes of cyber incidents remains human error. From clicking on phishing emails to using weak passwords, humans are often responsible for breaches in operational data and other sensitive information. For packaging companies, where teams work across production lines, offices and remote locations, awareness and training are essential.

Building a culture of cybersecurity starts with communication. Staff should understand not only what the risks are, but also why their role matters in preventing them. This means regular briefings, practical examples and simple procedures for reporting suspicious activity.

Collaboration Across the Supply Chain

Working with supply chain partners on cybersecurity is now as important as meeting quality or sustainability goals. Even smaller packaging businesses may be asked by retailers to follow certain security standards before signing contracts. By setting clear expectations and sharing best practices, small businesses can protect themselves and build trust with clients.

By setting clear standards and communicating them early, packaging businesses can not only protect themselves but also build trust with clients. Shared audits, standardised risk assessments and coordinated responses to incidents can make the whole network stronger.

Step-by-Step Incident Response to Protect Production Continuity

When a cyber incident hits a packaging operation, every second counts. The goal isn’t just to fix the issue, but also to keep production lines and serialization systems running as smoothly as possible. Start by identifying what’s been affected and isolate compromised networks fast to stop the spread.

Contain the threat by disconnecting infected systems, changing credentials, brokering or disabling vendor tunnels, and patching vulnerabilities immediately. Once the threat is neutralised, restore operations from verified backups and run a full post-incident review. Track a few simple KPIs: time to detect and recover, backup restore success rate, and reduction of single points of failure on the line.

The final step is communication. Let relevant teams, suppliers and partners know what’s happened and how it’s being resolved. Regular testing and updating of your incident response plan helps prevent downtime and financial loss, a crucial step when every hour of disruption can cost thousands.

Future-Proofing the Digital Packaging Landscape

As automation, AI and connected devices continue to shape the packaging sector, cybersecurity will remain an ongoing priority. Emerging technologies bring both benefits and new vulnerabilities, from smart labelling systems that track product journeys to AI-powered analytics that forecast demand.

The most successful businesses will be those that embed security into every stage of their digital journey, from design and manufacture to labeling and distribution. That means not treating security as a one-off project but as a continuous process of improvement.

The shift to a digitally connected packaging environment doesn’t have to be risky. By combining technical defences, staff awareness and shared responsibility across the supply chain, companies can stay both efficient and secure.

About: Tyler Owen - Vice President of Product Management for Cybersecurity Solutions at VikingCloud

Tyler serves as the Sr. Director of Product Management for Managed Security Services at VikingCloud. His extensive experience encompasses the entire lifecycle of Information Security infrastructure projects, from pre-sales and planning through to implementation, daily maintenance, and management. Tyler's expertise includes overseeing people, processes, policies, budgets, and resources, ensuring comprehensive security measures that protect and enhance IT infrastructures.

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