How many (2-part) cartridges do I need to be filling to justify an automated filling system?

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How many cartridges do I need to be filling to justify an automated filling system?

Mid to larger sized 2-component cartridges.

This is a question we are asked by Adhesive Manufacturers and Toll Fillers alike, and there are various considerations to be made, so rather than trying to answer it definitively we thought it would be better to offer a comparison across different scenarios and let you be the judge.

The comparison will be between a Semi-automatic Filling System, and an Automatic Filling System, based on ‘Mid to larger’ sized 2-component cartridge (200 to 600ml + range); costs and outputs will be based on what is common in this cartridge size range.

To read our blog on Small Cartridges Click Hear

Throughout the scenarios some items remain fixed, and some vary

Fixed items

1) The spec, output, and cost of the equipment

  • Semi-automatic system consists of a Semi-automatic Cartridge Filling Machine and a Semi-automatic Piston Insertion Station, each typically giving an output of 4 cartridges a minute, but each requiring an operator. At a cost of £60,000 GBP
  • Automated Cartridge Filling System, capable of giving an output of 10 cartridges a minute. Only requiring one operator. At a cost of £300,000

2) The Cost of labor – £10 Per Hour.

3) The Time Periods – in years

Variable items

1) The demand i.e., the number of cartridges that must be filled in a year.

2) The number of shifts that can be put on.

Caveats

For the purposes of this example we needed to settle on a finite time period the machine would be running for, so we chose 10 years (this is not an indication of the total service life of any equipment).

Both equipment cost, and outputs will vary both up and down, depending on the configuration and cartridge size (the prices and output chosen are fair averages rather than definitive).

Abbreviations

  • Semi-Automatic Cartridge Filling System – Semi-auto
  • Automatic Cartridge Filling System – Automatic

Point to remember

  • To achieve 4 Cartridges per minute with the Semi-auto, 2 Operators are required.
  • To achieve 10 Cartridges per minute with the Automatic, 1 Operator is required.

 

Scenario 1 – 100,000 cartridges a year

Semi-Auto outlay of 60,000 GBP

Manhours required – 833

Cost of Equipment and labor over 10 years

£ 143,300

 Automatic outlay of 300,000 GBP

Manhours required – 167

Cost of Equipment and labor over 10 years

£ 316,700

 

Scenario 2 – 200,000 cartridge a year

Semi-Auto outlay of 60,000 GBP

Manhours required – 1,667

Cost of Equipment and labor over 10 years

£ 226,700

 Automatic outlay of 300,000 GBP

Manhours required – 333

Cost of Equipment and labor over 10 years

£ 333,333

 

Scenario 3 – 300,000 cartridges a year (at this point a second shift or second machine would be required on Semi-auto)

(2nd shift)

Semi-Auto outlay of 60,000 GBP

Manhours required – 2,500

Cost of Equipment and labor over 10 years

£ 310,000

  

Automatic outlay of 300,000 GBP

Manhours required – 500

Cost of Equipment and labor over 10 years

£ 350,000
(2nd machine)

Semi-Auto outlay of 120,000 GBP

Manhours required – 2,500

Cost of Equipment and labor over 10 years

£ 370,000

  

 

Scenario 4 – 400,000 cartridges a year

(2nd shift)

Semi-Auto outlay of 60,000 GBP

Manhours required – 3,333

Cost of Equipment and labor over 10 years

£ 393,300

  

Automatic outlay of 300,000 GBP

Manhours required – 667

Cost of Equipment and labor over 10 years

£ 366,700
(2nd machine)

Semi-Auto outlay of 120,000 GBP

Manhours required – 3,333

Cost of Equipment and labor over 10 years

£ 453,300

  

 

Scenario 5 – 500,000 cartridges a year

(2nd shift)

Semi-Auto outlay of 60,000 GBP

Manhours required – 4,167

Cost of Equipment and labor over 10 years

£ 476,700

  

Automatic outlay of 300,000 GBP

Manhours required – 833

Cost of Equipment and labor over 10 years

£ 383,300
(2nd machine)

Semi-Auto outlay of 120,000 GBP

Manhours required – 4,167

Cost of Equipment and labor over 10 years

£ 536,700

  

 

Scenario 6 – 600,000 cartridges a year (at this point a third shift or a third machine would be required on Semi-auto)

(3rd shift)

Semi-Auto outlay of 60,000 GBP

Manhours required – 5,000

Cost of Equipment and labor over 10 years

£ 560,000

  

Automatic outlay of 300,000 GBP

Manhours required – 1,000

Cost of Equipment and labor over 10 years

£ 400,000
(3rd machine)

Semi-Auto outlay of 180,000 GBP

Manhours required – 5,000

Cost of Equipment and labor over 10 years

£ 680,000

  

 

Scenario 7 – 700,000 cartridges a year

(3rd shift)

Semi-Auto outlay of 60,000 GBP

Manhours required – 5,833

Cost of Equipment and labor over 10 years

£ 643,300

  

Automatic outlay of 300,000 GBP

Manhours required – 1,167

Cost of Equipment and labor over 10 years

£ 416,700
(3rd machine)

Semi-Auto outlay of 180,000 GBP

Manhours required – 5,833

Cost of Equipment and labor over 10 years

£ 763,300

  

 

Scenario 8 – 800,000 cartridges a year (at this point a second machine and second shift, or a fourth machine would be required on Semi-auto)

(2nd machine and 2nd shift)

Semi-Auto outlay of 120,000 GBP

Manhours required – 6,667

Cost of Equipment and labor over 10 years

£ 786,700

  

Automatic outlay of 300,000 GBP

Manhours required – 1,333

Cost of Equipment and labor over 10 years

£ 433,300
(4th machine)

Semi-Auto outlay of 240,000 GBP

Manhours required – 6,667

Cost of Equipment and labor over 10 years

£ 906,700

  

 

Scenario 9 – 900,000 cartridges a year

(2nd machine and 2nd shift)

Semi-Auto outlay of 120,000 GBP

Manhours required – 7,500

Cost of Equipment and labor over 10 years

£ 870,000

  

Automatic outlay of 300,000 GBP

Manhours required – 1,500

Cost of Equipment and labor over 10 years

£ 450,000
(4th machine)

Semi-Auto outlay of 240,000 GBP

Manhours required – 7,500

Cost of Equipment and labor over 10 years

£ 990,000

  

 

Scenario 10 – 1,000,000 cartridges a year

(2nd machine and 2nd shift)

Semi-Auto outlay of 120,000 GBP

Manhours required – 8,333

Cost of Equipment and labor over 10 years

£ 953,300

  

Automatic outlay of 300,000 GBP

Manhours required – 1,667

Cost of Equipment and labor over 10 years

£ 466,700
(4th machine)

Semi-Auto outlay of 240,000 GBP

Manhours required – 8,333

Cost of Equipment and labor over 10 years

£ 1,073,300

  

 

We have excluded consideration of downstream processes e.g., labeling, boxing-up, and palletizing. And only run the calculations to 1,000,000 cartridges per year.

 

If you would like us to calculate specific scenarios for your situation, please get in touch.

 

Or if you would like to To read our blog on Small Cartridges Click Hear