Automating Carton Packaging (200 Boxes per Hour)

1. Scenario Overview

The business currently processes 200 boxes per hour using either manual or semi-automatic workstations. Here, we assess the workflow before and after the introduction of the LINEBOX-03 Packaging Line (720 boxes/h).

• Required throughput: 200 boxes/h
• Machine capacity: 720 boxes/h → operates at a small fraction of its capability → excellent reliability
• Shift pattern: 8 hours per day, 22 days per month
• Machine price: €15,499

2. ROI Calculation (200 Boxes/Hour)

Labour cost reduction

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

3. Operational Benefits

Reliability & Capacity

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

Quality

• Cartons are formed and sealed to a high standard
• Controlled tape length minimises tape consumption
• Fewer returns and less rework required

Space & Workload Reduction

• Replaces two manual stations with a single automated line
• Requires just one operator for loading and monitoring

Scalability

• If output rises from 200 to 300, 400, or even 720 per hour, no extra staff are needed.

4. Financial Outcome After One Year

Total annual savings

• Labour: €42,240 per year
• Reduced tape wastage: 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
Annual benefit: approx. €43,000
Net gain after one year: around €27,000 profit

5. Conclusion

Operating at 200 boxes per hour, the LINEBOX-03 packaging line delivers the following advantages:

• Labour costs reduced by 50%
• Monthly savings of €3,520
• 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 additional personnel