Dayuan Automated Paper Cone and Carton Packaging Line Helps European Snack Manufacturer Cut Labor Costs by 60%
Case Study: Automated Paper Cone & Carton Packaging Line for a European Snack Manufacturer
Customer Background
A fast-growing snack food manufacturer in Europe was struggling to keep up with rising orders for ice cream cones, hamburger boxes and takeaway food packaging. Production still relied heavily on manual forming and separate semi-automatic machines, which caused low output, inconsistent quality, high reject rates and ever-increasing labor costs.
The Challenge
- Manual paper cone forming limited daily output and created food-safety and hygiene risks.
- Separate machines for cone making, box erecting and window patching slowed down the entire production flow.
- Unstable box dimensions and high reject rates damaged the customer's brand image with retail chains.
- A regional labor shortage and rising wages made manual production financially unsustainable.
The Solution: A Fully Integrated Dayuan Packaging Line
After evaluating several suppliers, the customer chose Dayuan Industrial Co., Ltd., a professional manufacturer of eco-friendly paper processing machines established in 1995, with more than 20 years of experience and exports to more than 70 countries. Dayuan's engineers designed a complete, integrated production solution covering the entire packaging process:
| Production Stage | Dayuan Machine | Key Benefit |
|---|---|---|
| Ice cream cone forming | Automatic Paper Cone Machine (dual-lane) | Up to 400 pcs/min with food-grade precision forming |
| Snack box erecting | Carton Erecting Machine L1560/4-A | Up to 800 pcs/min, CE certified, low noise, 3-8 corner box options |
| Window film lamination | Window Patching Machine TC-1100 | 200-400 pcs/min, servo feeder, high-precision diaphragm cutting |
| Punching & slitting | Cone Sleeve Punching Machine / Roll Paper Slitter | Consistent, accurate blanks for downstream forming |
| Printing & die-cutting | Flexographic Printing / Automatic Die Cutting Machine | Complete in-house decoration and blank preparation |
Implementation & Quality Assurance
Dayuan delivered the line with strict quality control: every machine was 100% inspected and ran a 72-hour continuous no-stop test before shipment. The machines were packed in strong fumigated wooden cases for the European export route, and a Dayuan technician was arranged for on-site installation and operator training. The customer also received a one-year warranty, free vulnerable spare parts (including gear boxes), and lifetime technical support.
Results After 6 Months of Operation
| KPI | Before (Manual / Semi-auto) | After (Dayuan Line) |
|---|---|---|
| Production speed | About 80 pcs/min | Up to 800 pcs/min |
| Workers required per shift | 12 workers | 3 workers |
| Labor cost | Baseline | Reduced by 60% |
| Reject rate | 5-8% | Below 1% |
| Daily output | Baseline | Doubled |
| Payback period | - | Under 18 months |
Why the Customer Chose Dayuan
- More than 20 years of manufacturing expertise since 1998.
- CE-certified machines designed to European standards.
- Four self-innovative product series ranking first in the domestic market.
- Products exported to more than 70 countries with consistently favorable reviews.
- Complete after-sales service: 72-hour test reports, free samples in 1-3 days, 45-day production lead time, one-year warranty and lifetime spare parts supply.
Conclusion
By switching to the Dayuan automated paper cone and carton packaging line, the customer achieved a 60% reduction in labor costs, doubled daily output and improved product consistency to below 1% reject rate - all while meeting strict European food-contact safety requirements. The project paid back in under 18 months and positioned the manufacturer for further expansion into new retail markets. Dayuan continues to support the customer's growth with spare parts, technical service and upgrades for the complete box-making production line.
