Carton Packaging Automation (200 Boxes per Hour)

1. Scenario Overview

The company currently packs 200 boxes per hour using either manual or semi-automatic stations. Here, we compare the workflow before and after implementing the LINEBOX-03 Packaging Line (720 boxes per hour).

• Required throughput: 200 boxes per hour
• Machine capacity: 720 boxes per hour → operates at a very low load → ensures high reliability
• Shift: 8 hours per day, 22 days per month
• Machine price: €15,499

2. ROI Calculation (200 Boxes per Hour)

Labor Savings

Before: €40 per hour
After: €20 per hour
Savings: €20 per hour

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 maximum speed, which results in minimal wear and a long service life.
• Delivers consistent output, unaffected by operator fatigue or inconsistency.

Quality

• Cartons are formed and sealed perfectly every time
• Controlled tape length reduces tape consumption
• Less rework and fewer returns

Space & Workload Reduction

• One automated line replaces two manual workstations
• Only a single operator is required (for loading and monitoring)

Scalability

• If production increases from 200 to 300, 400, or even 720 per hour, no additional labor is needed.

4. Financial Outcome After One Year

Total Annual Savings

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

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

Net Benefit After 12 Months

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

5. Conclusion

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

• 50% reduction in labor expenses
• €3,520 in monthly savings
• Payback period of 4.4 months
• Robust profitability over the long term
• Noticeably greater consistency, quality, and process control
• Sufficient capacity for future expansion without hiring additional personnel