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?
Small 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 Smaller-sized 2-component cartridges (.e.g. 50, 25, 10mls).
Typically with small cartridges, the machine cost will vary depending on whether the Adhesive can be gravity fed (lower viscosity), or whether some positive pressure is needed (higher viscosity) – so we have given scenarios for both; first scenarios 1 to 10 for a lower viscosity marked with (LV), and then scenarios 1 to 10 for a higher viscosity marked with (HV)
Throughout the scenarios some items remain fixed, and some vary
Fixed items
1) The spec, output, and cost of the equipment
- Semi-automatic system (LV) consisting of a Semi-automatic Cartridge Filling Machine and a Semi-automatic Piston Insertion Station, each typically giving an output of 6 cartridges a minute, but each requiring an operator. At a cost of £22,000 GBP
- Semi-automatic system (HV) consisting of a Semi-automatic Cartridge Filling Machine and a Semi-automatic Piston Insertion Station, each typically giving an output of 6 cartridges a minute, but each requiring an operator. At a cost of £50,000 GBP
- Automated Cartridge Filling System (LV), capable of giving an output of 20 cartridges a minute. Only requiring one operator. At a cost of £222,000
- Automated Cartridge Filling System (HV), capable of giving an output of 20 cartridges a minute. Only requiring one operator. At a cost of £250,000
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
- System for Lower viscosity – (LV)
- System for Higher viscosity – (HV)
Point to remember
- To achieve 6 Cartridges per minute with the Semi-auto 2 Operators are required.
- To achieve 20 Cartridges per minute with the Automatic 1 Operator is required.
(LV) Scenarios
(LV) Scenario 1 – 200,000 cartridges a year
| Semi-Auto outlay of 22,000 GBP
Manhours required – 1,111 Cost of Equipment and labor over 10 years 133,100 |
Automatic outlay of 222,000 GBP
Manhours required – 167 Cost of Equipment and labor over 10 years 238,000 |
(LV) Scenario 2 – 400,000 cartridge a year (at this point a second shift or second machine would be required on Semi-auto)
| (2nd shift)
Semi-Auto outlay of 22,000 GBP Manhours required – 2,222 Cost of Equipment and labor over 10 years 244,200 |
Automatic outlay of 222,000 GBP Manhours required – 333 Cost of Equipment and labor over 10 years 255,300 |
| (2nd machine)
Semi-Auto outlay of 44,000 GBP Manhours required – 2,222 Cost of Equipment and labor over 10 years 266,200 |
(LV) Scenario 3 – 600,000 cartridges a year
| (2nd shift)
Semi-Auto outlay of 22,000 GBP Manhours required – 3,333 Cost of Equipment and labor over 10 years 355,300 |
Automatic outlay of 222,000 GBP Manhours required – 500 Cost of Equipment and labor over 10 years 272,000 |
| (2nd machine)
Semi-Auto outlay of 44,000 GBP Manhours required – 3,333 Cost of Equipment and labor over 10 years 377,300 |
(LV) Scenario 4 – 800,000 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 22,000 GBP Manhours required – 4,444 Cost of Equipment and labor over 10 years 466,400 |
Automatic outlay of 222,000 GBP Manhours required – 667 Cost of Equipment and labor over 10 years 288,700 |
| (3rd machine)
Semi-Auto outlay of 66,000 GBP Manhours required – 4,444 Cost of Equipment and labor over 10 years 510,400 |
(LV) Scenario 5 – 1,000,000 cartridges a year
| (3rd shift)
Semi-Auto outlay of 22,000 GBP Manhours required – 5,556 Cost of Equipment and labor over 10 years 577,600 |
Automatic outlay of 222,000 GBP Manhours required – 833 Cost of Equipment and labor over 10 years 305,300 |
| (3rd machine)
Semi-Auto outlay of 66,000 GBP Manhours required – 5,556 Cost of Equipment and labor over 10 years 621,600 |
(LV) Scenario 6 – 1,200,000 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 44,000 GBP Manhours required – 6,667 Cost of Equipment and labor over 10 years 710,700 |
Automatic outlay of 222,000 GBP Manhours required – 1,000 Cost of Equipment and labor over 10 years 322,000 |
| (4th machine)
Semi-Auto outlay of 88,000 GBP Manhours required – 6,667 Cost of Equipment and labor over 10 years 754,700 |
(LV) Scenario 7 – 1,400,000 cartridges a year
| (2nd machine and 2nd shift)
Semi-Auto outlay of 44,000 GBP Manhours required – 7,778 Cost of Equipment and labor over 10 years 821,800 |
Automatic outlay of 222,000 GBP Manhours required – 1,167 Cost of Equipment and labor over 10 years 338,700 |
| (4th machine)
Semi-Auto outlay of 88,000 GBP Manhours required – 7,778 Cost of Equipment and labor over 10 years 865,800 |
(LV) Scenario 8 – 1,600,000 cartridges a year (at this point a second machine and third shift, or a fifth machine would be required on Semi-auto)
| (2nd machine and 3rd shift)
Semi-Auto outlay of 44,000 GBP Manhours required – 8,889 Cost of Equipment and labor over 10 years 932,900 |
Automatic outlay of 222,000 GBP Manhours required – 1,333 Cost of Equipment and labor over 10 years 355,300 |
| (5th machine)
Semi-Auto outlay of 110,000 GBP Manhours required – 8,889 Cost of Equipment and labor over 10 years 998,900 |
(LV) Scenario 9 – 1,800,000 cartridges a year
| (2nd machine and 3rd shift)
Semi-Auto outlay of 44,000 GBP Manhours required – 10,000 Cost of Equipment and labor over 10 years 1,044,000 |
Automatic outlay of 222,000 GBP Manhours required – 1,500 Cost of Equipment and labor over 10 years 372,000 |
| (5th machine)
Semi-Auto outlay of 110,000 GBP Manhours required – 10,000 Cost of Equipment and labor over 10 years 1,110,000 |
(LV) Scenario 10 – 2,000,000 cartridges a year (at this point a third machine and second shift, or a sixth machine would be required on Semi-auto)
| (3rd machine and 2nd shift)
Semi-Auto outlay of 66,000 GBP Manhours required – 11,111 Cost of Equipment and labor over 10 years 1,177,100 |
Automatic outlay of 222,000 GBP Manhours required – 1,667 Cost of Equipment and labor over 10 years 388,700 |
| (6th machine)
Semi-Auto outlay of 132,000 GBP Manhours required – 11,111 Cost of Equipment and labor over 10 years 1,243,100 |
(HV) Scenarios
(HV) Scenario 1 – 200,000 cartridges a year
| Semi-Auto outlay of 50,000 GBP
Manhours required – 1,111 Cost of Equipment and labor over 10 years 161,100 |
Automatic outlay of 250,000 GBP
Manhours required – 167 Cost of Equipment and labor over 10 years 266,700 |
(HV) Scenario 2 – 400,000 cartridge a year (at this point a second shift or second machine would be required on Semi-auto)
| (2nd shift)
Semi-Auto outlay of 50,000 GBP Manhours required – 2,222 Cost of Equipment and labor over 10 years 272,200 |
Automatic outlay of 250,000 GBP Manhours required – 333 Cost of Equipment and labor over 10 years 283,300 |
| (2nd machine)
Semi-Auto outlay of 100,000 GBP Manhours required – 2,222 Cost of Equipment and labor over 10 years 322,200 |
(HV) Scenario 3 – 600,000 cartridges a year
| (2nd shift)
Semi-Auto outlay of 50,000 GBP Manhours required – 3,333 Cost of Equipment and labor over 10 years 383,300 |
Automatic outlay of 250,000 GBP Manhours required – 500 Cost of Equipment and labor over 10 years 300,000 |
| (2nd machine)
Semi-Auto outlay of 100,000 GBP Manhours required – 3,333 Cost of Equipment and labor over 10 years 433,300 |
(HV) Scenario 4 – 800,000 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 50,000 GBP Manhours required – 4,444 Cost of Equipment and labor over 10 years 494,400 |
Automatic outlay of 250,000 GBP Manhours required – 667 Cost of Equipment and labor over 10 years 316,700 |
| (3rd machine)
Semi-Auto outlay of 150,000 GBP Manhours required – 4,444 Cost of Equipment and labor over 10 years 594,400 |
(HV) Scenario 5 – 1,000,000 cartridges a year
| (3rd shift)
Semi-Auto outlay of 50,000 GBP Manhours required – 5,556 Cost of Equipment and labor over 10 years 605,600 |
Automatic outlay of 250,000 GBP Manhours required – 833 Cost of Equipment and labor over 10 years 333,300 |
| (3rd machine)
Semi-Auto outlay of 150,000 GBP Manhours required – 5,556 Cost of Equipment and labor over 10 years 705,600 |
(HV) Scenario 6 – 1,200,000 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 100,000 GBP Manhours required – 6,667 Cost of Equipment and labor over 10 years 766,700 |
Automatic outlay of 250,000 GBP Manhours required – 1,000 Cost of Equipment and labor over 10 years 350,000 |
| (4th machine)
Semi-Auto outlay of 200,000 GBP Manhours required – 6,667 Cost of Equipment and labor over 10 years 866,700 |
(HV) Scenario 7 – 1,400,000 cartridges a year
| (2nd machine and 2nd shift)
Semi-Auto outlay of 100,000 GBP Manhours required – 7,778 Cost of Equipment and labor over 10 years 877,800 |
Automatic outlay of 250,000 GBP Manhours required – 1,167 Cost of Equipment and labor over 10 years 366,700 |
| (4th machine)
Semi-Auto outlay of 200,000 GBP Manhours required – 7,778 Cost of Equipment and labor over 10 years 977,800 |
(HV) Scenario 8 – 1,600,000 cartridges a year (at this point a second machine and third shift, or a fifth machine would be required on Semi-auto)
| (2nd machine and 3rd shift)
Semi-Auto outlay of 100,000 GBP Manhours required – 8,889 Cost of Equipment and labor over 10 years 988,900 |
Automatic outlay of 250,000 GBP Manhours required – 1,333 Cost of Equipment and labor over 10 years 383,300 |
| (5th machine)
Semi-Auto outlay of 250,000 GBP Manhours required – 8,889 Cost of Equipment and labor over 10 years 1,138,900 |
(HV) Scenario 9 – 1,800,000 cartridges a year
| (2nd machine and 3rd shift)
Semi-Auto outlay of 100,000 GBP Manhours required – 10,000 Cost of Equipment and labor over 10 years 1,100,000 |
Automatic outlay of 250,000 GBP Manhours required – 1,500 Cost of Equipment and labor over 10 years 400,000 |
| (5th machine)
Semi-Auto outlay of 250,000 GBP Manhours required – 10,000 Cost of Equipment and labor over 10 years 1,250,000 |
(HV) Scenario 10 – 2,000,000 cartridges a year (at this point a third machine and second shift, or a sixth machine would be required on Semi-auto)
| (3rd machine and 2nd shift)
Semi-Auto outlay of 150,000 GBP Manhours required – 11,111 Cost of Equipment and labor over 10 years 1,261,100 |
Automatic outlay of 250,000 GBP Manhours required – 1,667 Cost of Equipment and labor over 10 years 416,700 |
| (6th machine)
Semi-Auto outlay of 300,000 GBP Manhours required – 11,111 Cost of Equipment and labor over 10 years 1,411,100 |
We have excluded consideration of downstream processes e.g., labeling, boxing-up, and palletizing. And only run the calculations to 2,000,000 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 read our blog on Mid to Large sided Cartridges Click Hear