Use Case – FLEX BOX Semi-Automatic Case Erector

The Challenge

An e-commerce fulfillment warehouse located near Graz handles about 480 cartons each day, primarily medium-sized boxes. Previously, all cases were assembled manually at the start of the packing line. One team member spent most of their shift opening flat boxes, folding the bottoms, and holding them in place while packers loaded the products.

This manual approach capped throughput at roughly 2 cartons per minute and caused a consistent bottleneck. Operators experienced wrist and shoulder discomfort from repetitive folding, and supervisors often had to assign a second person during busy times, which increased labor costs per shipment.

Manual Process

With the manual system, one dedicated worker managed case forming, with packers stepping in to help during peak periods. Cycle times varied and ergonomics were suboptimal.

Before Automation:

• Daily output: 480 cartons/day
• Cycle time per carton: 40 seconds/carton (includes opening, squaring, folding, and holding)
• Total time per day: 480 × 40 seconds = 19,200 seconds ≈ 320 minutes (5.3 hours/day)
• Extra help time: ~1.1 hours/day (packers assisting during busy periods)
• Total daily forming labor: ≈6.4 hours/day
• Labor expense: 6.4 hours × €25/hour = €160/day
• Rework/issues: Roughly 3% of cartons required refolding or re-taping due to poorly squared bottoms

The forming station often slowed down the entire line whenever the main operator was interrupted or needed a break. In addition to lost time, management recorded several repetitive strain complaints per quarter linked directly to manual folding and holding of cases.

Automated Solution

The warehouse added the FLEX BOX Semi automatic Case Erector at the start of the packing line, connecting it to an existing carton sealer. Now, a single operator loads blanks into the magazine and places them into the machine; the erector pneumatically folds the bottom flaps and keeps the box upright for easy filling.

After Installing FLEX BOX Semi automatic Case Erector:

• The machine runs at 60% of its top speed for consistent performance
• Actual forming rate: ≈4 cartons/minute at 60% of 6–7 cartons/min
• Updated cycle time: 15 seconds/carton (including placement and transfer)
• Total time per day: 480 × 15 seconds = 7,200 seconds = 120 minutes (2.0 hours/day)
• Extra coordination/short breaks: ~1.3 hours/day
• Total daily forming labor: ≈3.3 hours/day
• Labor expense: 3.3 hours × €25/hour ≈ €82/day
• Quality gains: rework dropped from 3% to 0.5% of cartons due to reliably squared bottoms

The FLEX BOX eliminated the need for packers to help with forming. The dedicated operator now spends less than half a shift on box erection and can assist with other duties, while ergonomics have improved thanks to the adjustable worktable and less manual folding.

ROI Calculation

Investment:
Machine cost: €2,199
Daily time before: ≈6.4 hours/day
Daily time after: ≈3.3 hours/day
Daily hours saved: 6.4 − 3.3 = 3.1 hours/day
Daily savings: 3.1 hours × €25/hour ≈ €77.50/day (rounded to €78/day)
Extra savings from less rework and overtime: ≈€22/day
Total daily savings: ≈€100/day
Monthly savings (22 working days): €100/day × 22 days = €2,200/month
Payback period: €2,199 ÷ €100/day ≈ 22 days (≈1.1 months)

Conclusion

With the FLEX BOX Semi automatic Case Erector, the e-commerce warehouse was able to eliminate a persistent bottleneck, reduce box forming labor by nearly half, and cut rework to a fraction of previous levels. The investment was recouped in just over a month, while also making work easier for operators and opening up additional capacity for future growth.

“Thanks to the FLEX BOX, we now form the same 480 cartons in about half the time, and our labor costs for forming dropped from €160 to about €80 per day. Achieving payback in roughly 22 days and reducing the workload for our team made this one of the fastest and most impactful upgrades we’ve made.” — Markus Huber, Operations Manager, E-Com Fulfilment GmbH / Graz, Austria