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

1. Scenario Overview

The business currently packs 200 boxes per hour using either manual or semi-automatic workstations. Here, we examine the process before and after the installation of the LINEBOX-03 Packaging Line (720 boxes per hour).

• Required output: 200 boxes per hour
• Machine throughput: 720 boxes per hour → operates at a fraction of its capacity → excellent reliability
• Shift pattern: 8 hours per day, 22 days per month
• Machine cost: €15,499

2. Key Metrics (Before vs After)

3. ROI Calculation (200 Boxes/Hour)

Labour savings

Prior to automation: €40/h
Following automation: €20/h
Saving: €20/h

Monthly savings

€20 × 8h × 22 days =
€3,520 per month

Payback period

€15,499 ÷ €3,520 ≈
4.4 months

Annual savings

€3,520 × 12 =
€42,240 per year

4. Operational Benefits

Reliability & Capacity

• The machine operates at under 30% of its rated speed, resulting in minimal wear and a long service life.
• Delivers steady performance without operator fatigue or inconsistency.

Quality

• Cartons are formed and sealed to a consistently high standard
• Lower tape consumption thanks to precise tape length control
• Fewer reworks and product returns

Space & Workload Reduction

• One automated line replaces two manual workstations
• Requires just a single operator for loading and monitoring

Scalability

• Should your output rise from 200 to 300, 400, or even 720 units per hour, no additional staff will be necessary.

5. Financial Outcome After One Year

Total annual savings

• Labour: €42,240 per year
• Reduced tape waste: approximately €600–€1,200 per year
• Lower costs from damage and rework: €300–€1,000 per year

Total projected benefit:
€43,000–€44,400 per year

Net benefit after 12 months

Machine price: €15,499
Yearly benefit: around €43,000
Net gain after one year: approximately €27,000 profit

6. Conclusion

At a throughput of 200 boxes per hour, the LINEBOX-03 packaging line delivers:

• 50% reduction in labour costs
• €3,520 saved each month
• Payback period of 4.4 months
• Excellent long-term profitability
• Marked improvements in consistency, quality, and process control
• Sufficient capacity for expansion without the need for extra personnel