When Big Promotions Hit, Manual Cartoning Becomes a Profit Risk for Biscuit Factories
Alyssa/ December 29, 2025 Return
If you run a biscuit factory, this probably sounds familiar.
Everything feels fine on normal days.
But when a big promotion is coming, you start to feel nervous.
Not because you can’t sell.
But because you’re not sure your cartoning can keep up.Get A Quote
Why Cartoning Is the First Thing to Break During Big Promotions
In the biscuit industry, big promotions mean:
- A large number of orders in a short time
- Tight delivery deadlines
- Very little room for mistakes
In many factories, the situation looks like this:
- Production is running at full speed
- Individual packs are moving smoothly
- Manual cartoning becomes unstable
Once cartoning slows down,
the whole line is forced to wait.Get A Quote
Why Manual Cartoning Has No Flexibility Under Pressure
Many factory owners think:
“If we don’t have enough people, we’ll just add more.”
But during short, high-pressure promotion periods,
manual cartoning has very little flexibility.Get A Quote
Temporary labor cannot scale quickly
- Temporary workers are not skilled enough
- Training time is limited
- Output depends heavily on individual experience
Repetitive work leads to fast fatigue
- Simple actions repeated all day
- Speed drops after long shifts
- Mistakes increase when pressure rises
Management ends up fixing problems on-site
- Unstable packing speed
- Overtime just to meet deadlines
- Managers stuck on the floor all day
This is not a people problem.
It’s a system problem.Get A Quote
The Hidden Profit Loss Most Factories Don’t Calculate
During promotions, manual cartoning causes losses that are easy to miss.
Shipping speed is silently reduced
- Cartoning slows down outbound flow
- Finished products wait longer
- Overall daily shipment volume drops
Order opportunities are missed
- Extra orders are delayed or declined
- Delivery promises become risky
- Growth potential is limited during peak demand
Extra costs keep adding up
- Overtime labor
- Rework and corrections
- Coordination and supervision time
These losses don’t show up as one big failure.
They quietly reduce your profit throughout the entire promotion period.Get A Quote
What Happens If Manual Cartoning Stays the Same
If cartoning still depends heavily on people
during the most critical time of the year,
the situation usually moves in the same direction.Get A Quote
Pressure becomes constant
- Every shipment feels urgent
- Small delays stack up quickly
Management focus is pulled away
- Daily packing issues dominate attention
- Long-term planning gets pushed aside
The entire system relies on people “holding on”
When they can’t,
the impact is often bigger than one delayed shipment.Get A Quote
How a Cartoning Machine Changes This Situation
Here we are talking about secondary packaging—
cartoning after individual packs,
with no direct contact with food.
Because of that,
this is the stage where reducing manual labor makes the most sense.Get A Quote
Labor dependence is reduced
- Fewer workers are needed at the cartoning stage
- Output is less affected by staff changes
Packing rhythm becomes stable
- Speed is consistent across shifts
- Peak periods are easier to manage
Last-minute labor fixes are avoided
- Less reliance on temporary workers
- Fewer emergency adjustments
It’s not about removing people completely.
It’s about keeping the system stable when pressure is highest.Get A Quote
A Question Worth Thinking About Before the Next Promotion
For many biscuit factories,
the real risk during promotions is not production speed.
It is whether packaging can stay stable from start to finish.
If your next promotion starts earlier than expected,
and order volume rises quickly,
will your current cartoning setup still run smoothly every day?
If that question doesn’t have a clear answer,
cartoning may already be the part of the process
that deserves a closer look.Get A Quote
| Industry | Product | Packaging Stage | Main Issue | Relevant Solution |
|---|---|---|---|---|
| Food | Biscuit | Secondary Packaging (Cartoning) | Labor instability during promotions | Automatic Cartoning Machine |
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