Two-Meter-Long Corrugated Cartons: A Cost-Effective Automation Solution

Client Overview Our client is a manufacturer specializing in the production of large-format corrugated cartons.

Due to the considerable size of their products—some measuring up to two meters in length and constructed with five-layer corrugated board—manual carton gluing had become increasingly challenging. Production efficiency was low, labor requirements were high, and maintaining consistent product quality was difficult.

The client sought an automated folder gluing solution that could significantly improve productivity while reducing labor costs.

Challenge The client’s production process relied entirely on manual carton gluing.

Their existing operation faced several limitations:

• Three workers were required per production team
• Output was limited to fewer than 200 cartons per hour
• Only cold glue was used, with uneven manual pressure during carton bonding
• Physically demanding work led to employee turnover and increased workplace injury risks
• Production capacity constrained business growth and order expansion

The customer was looking for a reliable, easy-to-operate, and highly efficient solution that could deliver substantial productivity gains with a relatively low investment.

Project Scope The project focused on introducing:

• Single-piece and multi-piece folder gluer systems
• Compression delivery conveyors
• Counting and transverse transfer conveyors

The objective was to automate the production process, improve workflow efficiency, reduce labor requirements, and ensure consistent carton bonding quality and production output.

Our Team & Approach The client approached Benefit for comprehensive support covering equipment selection, production process optimization, and operational improvements.

Drawing on years of experience in packaging machinery applications, our team provided a complete turnkey solution, including:

• Production process analysis
• Equipment selection
• Installation and commissioning
• Operator training
• Technical support

How Benefit Added Value

Based on extensive manufacturing experience and a detailed understanding of the customer’s operational requirements, Benefit developed a customized solution that delivered measurable value.

1.Customized Production Analysis
We analyzed:
• Carton dimensions
• Board thickness
• Production workflow
• Manual handling challenges
This allowed us to determine the optimal equipment configuration for the client’s specific application.

2.Optimized Equipment Configuration
We recommended a combination of:
• Single-piece and multi-piece folder gluers
• Compression delivery systems
• Automated transfer conveyors
This solution significantly increased production efficiency while maintaining flexibility for different carton formats.

3.Standardized Operating Procedures
Benefit developed:
• Operating procedures
• Training materials
• Production guidelines
to minimize human error and ensure consistent production performance.

4.Low Investment, High Return
The selected solution required a relatively modest investment while delivering substantial productivity improvements and long-term labor cost savings.

Technical Research

Beyond production efficiency, the project also improved the overall working environment by reducing physical labor demands and simplifying operational workflows.
This contributed to:
• Better employee satisfaction
• Improved workplace safety
• Greater production stability
• Enhanced scalability for future growth

Prototype Development & Approval

At the beginning of the project, Benefit implemented a structured demonstration and approval process to ensure the proposed solution fully met the customer’s expectations.

Live Equipment Demonstration
A practical machine demonstration was conducted to showcase the equipment’s core capabilities and production performance.

Internal Validation
Our technical team completed installation, commissioning, and internal quality verification to ensure all performance targets were achieved.

Customer Evaluation & Approval
The customer was invited to evaluate:
• Equipment performance
• Production suitability
• Processing quality

After successful evaluation, the project proceeded to the procurement and implementation phase.

Comprehensive Solution Implementation

Once the project was approved, Benefit moved into full-scale implementation and technical support.

1. Final Equipment Configuration & Contract Agreement
Machine specifications, technical requirements, installation plans, and after-sales service terms were finalized and incorporated into the formal project agreement.

2. Advanced Pre-Delivery Testing
Before shipment, the equipment underwent comprehensive performance testing focusing on critical production parameters.
Performance Verification
Machine settings were optimized to ensure uniform and accurate adhesive application.
Quality Assurance
Finished cartons were inspected to verify both production output and product quality standards.
Standardization
Detailed operating manuals and safety procedures were developed to support efficient and safe operation.

3. On-Site Installation & Operator Training
Following delivery, Benefit engineers provided on-site technical support and operator training.
Training covered:
• Single-piece folder gluer operation
• Multi-piece folder gluer operation
• Auxiliary conveyor systems
• Production best practices
• Routine maintenance procedures
This ensured a smooth transition into full-scale production.

Final Results

Following implementation, the customer achieved substantial improvements in production efficiency and operational performance.

Significant Capacity Increase
Production output increased well beyond the previous manual production level of fewer than 200 cartons per hour.

Reduced Labor Requirements
Labor consumption was reduced by approximately 50%, resulting in significant long-term labor cost savings.

Automated Adhesive Application
Both hot-melt and cold-glue application processes were fully automated, ensuring:
• Consistent adhesive coverage
• Improved bonding quality
• Reduced operator dependency

Improved Product Consistency
The automated compression and bonding process delivered:
• More consistent carton quality
• Improved structural integrity
• Reduced variation between production batches

Greater Business Growth Potential
With higher productivity, lower operating costs, and improved quality consistency, the client gained the ability to accept larger order volumes and support future business expansion.

Conclusion
By implementing a carefully engineered combination of folder gluing and automated conveying systems, Benefit helped the client transform a labor-intensive production process into a highly efficient and scalable operation.
The result was a true low-investment, high-return solution, delivering:
✅ Higher production capacity
✅ Lower labor costs
✅ Improved product quality
✅ Better workplace conditions
✅ Increased business growth opportunities