Case Study: Automation of Carton Packaging (200 Boxes/Hour)

1. Scenario Overview

The company packs 200 boxes/hour using manual or semi-automatic stations. We compare the operation before vs after installing the LINEBOX-03 Packaging Line (720 boxes/h).

• Required throughput: 200 boxes/h
• Machine capacity: 720 boxes/h → runs at very low load → high reliability
• Shift: 8 hours/day, 22 days/month
• Machine price: €15,499

2. Key Metrics (Before vs After)

3. ROI Calculation (200 Boxes/Hour)

Labor savings

Before: €40/h
After: €20/h
Savings: €20/h

Monthly savings

€20 × 8h × 22 days =
€3,520/month

Payback period

€15,499 ÷ €3,520 ≈
4.4 months

Annual savings

€3,520 × 12 =
€42,240/year

4. Operational Benefits

Reliability & Capacity

• Machine runs at less than 30% of its maximum speed, ensuring extremely low wear and long lifespan.
• Consistent output without fatigue or variability.

Quality

• Perfect forming and sealing of cartons
• Reduced tape usage due to controlled tape length
• Lower rework and returns

Space & Workload Reduction

• Replaces two manual workstations with one automated line
• Only one operator needed (loading and supervision)

Scalability

• If production needs increase from 200 to 300, 400, or even 720/h, no extra labor is required.

5. Financial Outcome After One Year

Total annual savings

• Labor: €42,240/year
• Tape waste reduction: ~€600–€1,200/year
• Reduced damage/rework: €300–€1,000/year

Total estimated benefit:
€43,000 – €44,400/year

Net benefit after 12 months

Machine cost: €15,499
Annual benefit: approx. €43,000
Net return after year 1: ~€27,000 profit

6. Conclusion

At 200 boxes/hour, the LINEBOX-03 packaging line provides:

• 50% labor cost reduction
• €3,520/month savings
• 4.4-month payback
• Strong long-term profitability
• Significantly improved consistency, quality, and operational control
• Enough headroom for future growth without extra staff