Caption: The automatic facial tissue cartoning machine that replaced 8 manual operators, running at 130 boxes/min
Introduction
Labor costs are the single largest operating expense for tissue converters in Europe. When a mid-sized tissue manufacturer in Poland faced a 12% annual wage increase and persistent recruitment challenges, they decided to automate their packaging line. The result: a 60% reduction in packaging labor, a 10-month ROI, and a 35% increase in daily output.
This case study documents the complete project—from initial requirements through machine selection, installation, and financial results. The equipment was supplied by Wenzhou Shengtai Machinery, a Chinese cartoning machine manufacturer with 10+ years of experience and CE-certified equipment.
The Challenge: Manual Packaging Bottleneck
Company Profile
Location
- : Poland (Central Europe)
Products
- : Facial tissue, toilet rolls, kitchen towels
Production volume
- : ~80,000 boxes/day (single shift)
Packaging method
- : Manual boxing with 8 operators per shift
Labor cost
- : €1,200/month per operator (including social contributions)
Pain Points
Rising wages
1. : Poland's minimum wage increased 12% year-over-year, and skilled packaging operators commanded even higher premiums.
Recruitment difficulty
2. : High turnover and seasonal demand spikes made it impossible to maintain a stable workforce.
Inconsistent quality
3. : Manual boxing resulted in 2–3% defect rate (misfolded cartons, improper sealing, damaged products).
Output ceiling
4. : The manual line could not exceed 80,000 boxes/day without adding a second shift, which would double labor costs.
Ergonomic issues
5. : Repetitive motion injuries and fatigue-related errors were increasing worker compensation claims.
The Solution: Automatic Cartoning Machine Integration
Machine Selection Criteria
The buyer evaluated suppliers from Germany, Italy, and China. The decision criteria were:
Criteria |
Weight |
German Supplier |
Italian Supplier |
Shengtai (China) |
Speed (boxes/min) |
25% |
140 |
130 |
150 |
FOB Price |
30% |
€85,000 |
€72,000 |
€35,000 |
CE Compliance |
20% |
✓ Full |
✓ Full |
✓ Full |
Changeover Time |
10% |
15 min |
20 min |
10–20 min |
After-Sales Support |
10% |
On-site (€500/day) |
On-site (€400/day) |
Remote + local partner |
Lead Time |
5% |
16 weeks |
14 weeks |
4 weeks |
Shengtai won the bid with the best price-performance ratio: comparable speed and compliance at less than half the cost of European alternatives, with a significantly shorter lead time.
Machine Specifications
Model
- : Automatic High-Speed Horizontal Cartoning Machine (customizable)
Speed
- : 130 boxes/min (stable operating speed for facial tissue)
Carton range
- : 100–240mm (L) × 100–120mm (W) × 30–90mm (H)
Construction
- : 304 stainless steel shell, 10mm plexiglass safety panels
Control
- : Siemens PLC with 10-inch touch-screen HMI
Sealing
- : Tongue-type with optional hot-melt glue
Power
- : 8 kW, 380V/50Hz
Air
- : 0.5MPa, 100 L/min
Dimensions
- : 3,619 × 1,450 × 1,800mm
Weight
- : ~2,100 kg
Implementation Timeline
Phase |
Duration |
Activities |
Order placement |
Week 1 |
Contract signing, 30% T/T deposit |
Manufacturing |
Weeks 2–5 |
Assembly, wiring, 48-hour run test |
Factory acceptance test |
Week 5 |
Buyer's team tests with actual product via video |
Shipping |
Weeks 6–10 |
FOB Ningbo, ocean freight to Gdansk, customs clearance |
Installation |
Week 11 |
Unloading, positioning, power/air connection |
Commissioning |
Week 12 |
Remote video guidance, operator training, trial production |
Full production |
Week 13 |
Machine integrated into daily operations |
Total project duration: 13 weeks from order to full production.
Financial Results
Investment Breakdown
Item |
Cost (EUR) |
Machine (FOB) |
€35,000 |
Ocean freight (LCL to Gdansk) |
€1,800 |
Import duty (1.7%) |
€595 |
VAT (23% Poland) |
€8,577 |
Inland transport (Gdansk to factory) |
€600 |
Installation and commissioning (remote) |
Included |
Spare parts kit (2-year supply) |
€1,200 |
Total landed cost |
€47,772 |
Labor Savings
Metric |
Before (Manual) |
After (Automated) |
Savings |
Operators per shift |
8 |
2 |
6 operators |
Monthly labor cost |
€9,600 |
€2,400 |
€7,200/month |
Annual labor cost |
€115,200 |
€28,800 |
€86,400/year |
Defect rate |
2.5% |
0.3% |
2.2% reduction |
Daily output |
80,000 boxes |
108,000 boxes |
+35% |
ROI Calculation
Annual labor savings
- : €86,400
Annual defect cost reduction
- : ~€8,000 (based on material waste savings)
Total annual savings
- : €94,400
Total investment
- : €47,772
Payback period
- : €47,772 ÷ €94,400 × 12 =
6.1 months
Even using conservative assumptions (excluding the output increase benefit), the machine paid for itself in approximately 10 months.
Additional Benefits
Consistent quality
1. : Defect rate dropped from 2.5% to 0.3%, improving customer satisfaction.
Scalability
2. : The machine can run a second shift at minimal additional cost, doubling output if needed.
Worker safety
3. : Elimination of repetitive motion injuries reduced compensation claims.
Brand image
4. : Automated packaging produces more consistent carton appearance, strengthening the brand's retail presence.
Data tracking
5. : The PLC logs production counts, enabling accurate OEE (Overall Equipment Effectiveness) monitoring.
Lessons Learned
What Went Well
Supplier selection
- : Shengtai's CE-certified machine met all European compliance requirements without modification.
Remote commissioning
- : Video-guided installation worked smoothly, saving €3,000+ in engineer travel costs.
Spare parts planning
- : The 2-year spare parts kit prevented any production interruptions.
What Could Be Improved
Operator training
- : More extensive pre-shipment training at the factory would have reduced the learning curve.
Upstream integration
- : The existing flow wrapper needed a speed adjustment to match the cartoner's throughput. This was resolved but added 2 days to commissioning.
Documentation
- : The English user manual was adequate but could have included more troubleshooting flowcharts.
Conclusion & Next Step
This case study demonstrates that a well-selected cartoning machine from a reputable Chinese manufacturer can deliver European-quality performance at a fraction of the cost, with ROI in under a year. The key success factors were clear specifications, CE compliance verification, and proactive spare parts planning.
Want to calculate the ROI for your packaging line automation? Send us your current labor costs and production volume—we'll provide a customized ROI analysis → Shengtai Machinery has helped buyers in 20+ countries automate their packaging operations.
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