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

Posted on by devdev78910

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)

MetricBefore (Manual / Semi-auto)After (LINEBOX-03)
Throughput200 boxes/h200 boxes/h (machine capable of 720/h)
Operators needed2 operators1 operator
Labor cost per hour2 × €20 = €40/h€20/h
Labor savings—€20/h
Boxes per operator100/h200/h
Quality consistencyMediumHigh, stable forming & sealing
Error / reworkHigherSignificantly reduced
Monthly labor cost€40 × 176h = €7,040€20 × 176h = €3,520
Monthly savings—€3,520/month
Payback period—4.4 months

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