How a Cardboard Factory in Peru Cut Packaging Time by 80% and Achieved Fully Unmanned Operations with Dyehome's Integrated Packaging Line

How a Cardboard Factory in Peru Cut Packaging Time by 80% and Achieved Fully Unmanned Operations with Dyehome's Integrated Packaging Line

Summary: A leading cardboard manufacturer in Peru replaced manual packaging with Dyehome's 4-machine integrated line — covering machine, high-speed rotary arm wrapper, and two strapping machines. Packaging time dropped from 10 minutes to under 2 minutes per pallet, while reducing the workforce from multiple operators to fully unmanned operation.
The Challenge: Manual Packaging Couldn't Keep Up
The customer, one of Peru's established cardboard and corrugated box manufacturers, faced three critical packaging challenges that were holding back their entire production operation:
Challenge 1: Inconsistent Load Sizes Made Standardization Impossible
Challenge 2: Labor Costs Were Unsustainable
Challenge 3: Human Limitations in a 24/7 Operation
The Solution: A 4-Machine Integrated Packaging Line
After evaluating multiple equipment suppliers, the customer chose Dyehome to design and deliver a complete end-of-line packaging solution tailored to their specific requirements:
Equipment Model/Type Function
Top Sheet Covering Machine Dyehome Automatically places protective top sheets on every load
High-Speed Rotary Arm Wrapper Dyehome Wraps stretch film around pallets at high speed with pre-stretch technology
Automatic Strapping Machine ×2 Dyehome Applies horizontal and vertical straps for load security
Why This Configuration?
The key design decision was choosing a rotary arm wrapper over a turntable. Since the customer's loads include both palletized and non-palletized goods of varying sizes, the rotary arm's ability to wrap stationary loads was a perfect fit:
• No load rotation — eliminates the risk of unstable loads shifting during wrapping
• No weight limit — handles the heaviest cardboard bundles without a turntable platform constraint
• Flexible load handling — accommodates anything from small cartons to oversized irregular loads
The two strapping machines secure loads before wrapping, while the top sheet covering machine adds dust and moisture protection — creating a complete packaging workflow from a single supplier.

Why the Customer Chose Dyehome
The customer evaluated several suppliers before selecting Dyehome. Three factors made the difference:
1. Competitive Pricing with No Compromise on Quality
Dyehome's pricing was in the mid-range — not the cheapest, but offering the best value for the engineering quality and after-sales support included.
2. Responsive After-Sales Service
Throughout the installation and commissioning process, Dyehome's service team responded quickly to every request. Issues were resolved promptly, without deflection or delays.
3. Willingness to Customize Based on Feedback
When the customer raised suggestions for optimizing the equipment layout and workflow, Dyehome adopted them immediately. This collaborative approach — treating the customer as a partner rather than just a buyer — was the decisive factor.
The customer noted: "Communication with Dyehome has been smooth from day one. They listen, they adapt, and they follow through."
What Changed for the Customer
• Packaging speed increased by 5–10× — from 10 minutes per pallet to as little as 1–2 minutes
• Full unmanned operation achieved — workers transitioned from physical labor to equipment monitoring
• 24/7 production capability — machines don't need breaks, shifts, or holidays
• Consistent packaging quality — every load gets the same professional treatment, regardless of time of day or operator experience
• Scalable for growth — the line can handle increased volume without proportional labor increases

What This Means for Your Operation
If your packaging operation faces similar challenges — variable load sizes, high labor costs, or difficulty maintaining consistent quality — an integrated automated packaging line may be the answer.
Is This Solution Right for You?
This type of integrated line is ideal if you:
✅ Handle mixed load types (palletized and non-palletized)
✅ Need 24/7 packaging capacity
✅ Want to reduce packaging labor costs significantly
✅ Require consistent, professional packaging quality for every shipment
✅ Operate in industries like cardboard manufacturing, building materials, food & beverage, chemicals, or logistics
Dyehome's Product Range
Dyehome (大宏智能) is a professional manufacturer of end-of-line packaging equipment with over 20 years of production experience. Our product line includes:
• Turntable Stretch Wrappers — for standard pallet wrapping
• Rotary Arm Stretch Wrappers — for heavy, tall, or unstable loads
• Horizontal Wrappers — for long or irregular products
• Case Erectors & Sealers — for automated carton setup
• Palletizers — for automated pallet building
• Strapping Machines — for load securing
• Conveyor Systems — for line integration
Every solution is engineered to your specific load profile, throughput requirements, and facility layout.

Ready to Transform Your Packaging Line?
Contact Dyehome today for a free packaging line consultation. Tell us about your current operation, and we'll design a solution that delivers measurable ROI.