How an Indonesian Packaging Manufacturer Doubled Its Laminating Production Capacity

Client Overview Our client is a major packaging manufacturer in Indonesia, operating multiple high-speed laminating production lines for large-volume paper packaging products.

As production demand continued to grow, the company placed strong emphasis on:
• Increasing production capacity
• Improving operational efficiency
• Reducing labor intensity
• Controlling manufacturing costs
• Expanding order fulfillment capability

The client was looking for practical solutions that could support long-term growth while maintaining a safe and efficient production environment.

Challenge The customer’s primary bottleneck occurred at the manual sheet collection stage.

At the time:
• Production output was limited to approximately 2,000–3,000 sheets per hour
• Each high-speed laminating machine required two operators for sheet collection
• More than 16 workers were engaged in physically demanding collection tasks throughout the workshop

This created several operational challenges:
• High labor costs
• Increased employee turnover
• Higher risk of workplace injuries
• Reduced workforce motivation
• Limited production scalability

As order volumes continued to increase, the client urgently needed a reliable and efficient automatic sheet collection solution that could improve both productivity and cost performance.

Project Scope This project focused on upgrading the client’s high-speed laminating production lines through the implementation of eight automatic flip pile delivery systems.

The objective was to replace manual sheet collection with an automated solution that would provide:
• Stable and reliable operation
• Easy machine operation
• Increased production efficiency
• Reduced labor dependency

The project also required delivery, installation, and commissioning within a limited project timeline.

Our Team & Approach The client partnered with Benefit due to our extensive experience in machinery design, manufacturing, and production automation.

Our professional team provided a complete turnkey solution including:
• Equipment evaluation
• System selection
• Installation and commissioning
• Production training
• Quality control
• After-sales technical support

The project was led by a dedicated project manager and supported by technical engineers and installation specialists.

Under strict project supervision, a detailed implementation plan was developed covering:
• Production requirement analysis
• Equipment evaluation
• Prototype testing
• Manufacturing scheduling
• Installation planning

Every stage was carefully controlled to ensure successful project execution.

How Benefit Added Value

Benefit delivered substantial value through a combination of engineering expertise, project management, and process optimization.

1.Comprehensive Production AnalysisWe conducted a detailed assessment of:
• Existing production line configurations
• Operator workflows
• Equipment integration requirements
• Production bottlenecks
This ensured that the proposed solution would integrate seamlessly with the client’s existing manufacturing environment.

2.Optimized Equipment SelectionBased on the client’s objectives, we recommended a flip pile delivery system that offered:
• Stable performance
• High reliability
• Excellent cost-performance ratio
• Easy operation and maintenance
The selected solution aligned perfectly with the client’s productivity and investment goals.

3.Strict Quality ControlEach machine underwent multiple rounds of testing and fine-tuning to ensure:
• Stable operation
• Accurate positioning
• Reliable stacking performance
• Achievement of target production capacity
This rigorous process minimized commissioning risks and ensured consistent performance after installation.

4.Professional Negotiation & Delivery AssuranceBenefit worked closely with the client to ensure:
• Competitive equipment pricing
• Controlled project timelines
• Flexible installation arrangements
• Customized operator training programs

Through this structured approach, the customer achieved improvements in both production efficiency and operational safety.

Prototype Development & Approval

Based on the client’s production requirements, prototype testing was conducted using actual paper samples.
The evaluation focused on:

Capacity Verification
• Confirmation of target production output
• Continuous operation performance testing
Safety Evaluation
• Full-stack alarm system verification
• Operational safety assessment
• User-friendly operation review

Precision Optimization
• Positioning system adjustment
• Sheet collection accuracy testing
• Stack alignment verification

The test results were presented to the client, who expressed a high level of satisfaction with the performance and functionality of the solution.

Comprehensive Solution Implementation

Following project approval, Benefit established a comprehensive delivery and quality assurance framework.

1.Clear Specifications & Quality Standards A formal agreement was established covering:
• Equipment specifications
• Delivery schedules
• Detailed quality requirements
• Acceptance criteria
This ensured complete transparency and protected the client’s interests throughout the project.

2.Pre-Production Evaluation & Prototype Testing Before production began, comprehensive evaluations were conducted covering:
• Paper compatibility
• Production feasibility
• Capacity projections
• Return-on-investment expectations
Prototype testing ensured that the final production equipment would deliver results consistent with expectations.

3.Pre-Shipment Inspection Prior to shipment, Benefit engineers conducted thorough inspections covering:
• Mechanical accuracy
• Operating stability
• Noise levels
• Alarm system functionality
• Packaging quality
This comprehensive inspection process ensured that all equipment met performance standards before delivery.

Continuous Optimization & Technical Support

Through systematic project management and quality control, machine stability and operational precision were significantly improved.

During the client’s initial production phase, our engineering team identified force-adjustment inconsistencies on certain equipment units.

The issue was immediately investigated and resolved through:
• Mechanical parameter optimization
• Component performance adjustments
• Technical support and on-site guidance

After implementing these improvements, the equipment achieved higher operating efficiency and greater production stability, eliminating potential risks during the ramp-up stage.

Final Results

The implementation of eight automatic flip pile delivery systems generated substantial improvements across the client’s production operation.

•Production Capacity Doubled：The automatic collection system increased laminating line output from approximately:
3,000 sheets/hour → over 6,000 sheets/hour
resulting in a 100% increase in production capacity.

•Reduced Labor Costs：A single operator using a hydraulic pallet truck can now manage the output from two laminating machines simultaneously, significantly reducing labor requirements.

•Improved Working EnvironmentFeatures such as:
• Automatic stack collection
• Full-stack alarm systems
• Hydraulic pallet handling
greatly reduced worker fatigue and improved workplace safety.

Greater Business Expansion Capability
With significantly increased production capacity, the client gained the ability to accept more orders and support future business growth.

Conclusion
The successful delivery of eight automatic flip pile delivery systems demonstrates Benefit’s commitment to understanding customer needs and delivering practical, value-driven solutions.

Through equipment innovation, process optimization, and professional project execution, we helped the client achieve a true win-win outcome:
✅ Double production capacity
✅ Lower labor costs
✅ Improved workplace safety
✅ Greater operational stability
✅ Enhanced ability to support business growth