--- title: Doubling Capacity & Efficiency without Doubling Costs description: Optimizing your packaging lines can seem daunting, but our team is on point with finding opportunities for higher productivity greater efficiencies! image: //www.industrialpackaging.com/hubfs/Blogging_Images/2016_BLOGGING/tray-line.png --- ** ** [ Talk to an expert ](https://www.industrialpackaging.com/contact-us) - Categories ** - ** [Subscribe](https://www.industrialpackaging.com/blog-subscribe) [«  View All Posts](https://www.industrialpackaging.com/resources) ![Doubling Capacity & Efficiency without Doubling Costs](https://www.industrialpackaging.com/hubfs/Blogging_Images/2016_BLOGGING/tray-line.png) ![Blog Feature](https://cdn2.hubspot.net/hubfs/298890/blog-files/blog--cards-feature.png) [Subscribe](https://www.industrialpackaging.com/blog-subscribe) ![David Roberge](https://www.industrialpackaging.com/hubfs/Davids%20Headshot%202025%20IP%20-%20Dark%20Blue.jpg "David Roberge") By: [David Roberge](https://www.industrialpackaging.com/blog/author/david-roberge) on May 19th, 2016 ** Print/Save as PDF # Doubling Capacity & Efficiency without Doubling Costs [Equipment](https://www.industrialpackaging.com/blog/topic/equipment) | [The Business of Packaging](https://www.industrialpackaging.com/blog/topic/the-business-of-packaging) | [Supply Chain Services/ Contract Packaging](https://www.industrialpackaging.com/blog/topic/supply-chain-services-contract-packaging) | [Plant Performance](https://www.industrialpackaging.com/blog/topic/plant-performance) - Share: - [**](https://www.facebook.com/sharer/sharer.php?u=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput) - [**](https://twitter.com/intent/tweet?text=Doubling+Capacity+%26+Efficiency+without+Doubling+Costs&url=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput&via=) - [**](https://www.linkedin.com/shareArticle?url=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput&title=Doubling+Capacity+%26+Efficiency+without+Doubling+Costs&summary=Optimizing+your+packaging+lines+can+seem+daunting%2C+but+our+team+is+on+point+with+finding+opportunities+for+higher+productivity+greater+efficiencies%21) - [**](mailto:?body=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput) ## How we grew  our packaging line capacity and efficiency with a simple fix ![tray-line.png](https://www.industrialpackaging.com/hs-fs/hubfs/Blogging_Images/2016_BLOGGING/tray-line.png?width=128&name=tray-line.png "tray-line.png")Optimizing your packaging lines can seem daunting, but our team is on point when it comes to finding opportunities for higher productivity and driving greater efficiencies with minimal negative financial impact. This holds true in our facilities, and at our customers'. Check out how we were able to double our throughput with some minor adjustments:  ### The issue ![older-line-vs-newer-line-031181-edited.png](https://www.industrialpackaging.com/hs-fs/hubfs/Blogging_Images/2016_BLOGGING/older-line-vs-newer-line-031181-edited.png?width=400&name=older-line-vs-newer-line-031181-edited.png "older-line-vs-newer-line-031181-edited.png")We have 2 tray lines in our Leominster, MA facility.  One of the lines was running about 50% less efficient than the other in more than one way. This was attributed to older packaging equipment on the less efficient line, and also because it was more difficult to run product on it. Additionally, it was more costly on in labor, needing more people on the line to run the same product.  ### the REMEDY ![tray-line-new-throughput.png](https://www.industrialpackaging.com/hs-fs/hubfs/Blogging_Images/2016_BLOGGING/tray-line-new-throughput.png?width=399&name=tray-line-new-throughput.png "tray-line-new-throughput.png") The newer line has the capability to run faster, so we doubled our [headcount](https://www.industrialpackaging.com/blog/justifying-automatic-vs-manual-packaging-equipment) on the that line. This ended up doubling our throughput because the line had additional capability to run faster. We are now able to utilize the other line for more projects that require less packages per minute, and satisfy our higher demand customers with the faster tray line.    Looking for ways to optimize your packaging line throughput and efficiencies? [Talk to our Packaging pro's](https://www.industrialpackaging.com/packaging-consultation) today! [![Learn More](https://no-cache.hubspot.com/cta/default/386184/19951815-8cab-47dc-801e-e7fa3fdd14cc.png)](https://cta-redirect.hubspot.com/cta/redirect/386184/19951815-8cab-47dc-801e-e7fa3fdd14cc)   ### About David Roberge I help CPG brands find the right contract packaging partner through content that answers real questions. I get to do that alongside a team whose values actually match mine: respect, teamwork, and always getting better. I also appreciate the psychology behind decision-making. Outside of work you'll find me hiking with my partner and dog, learning German and Spanish, pulling tarot cards. - **Connect with David Roberge** - [**](https://www.linkedin.com/in/davidroberge) - [**](mailto:david.roberge@industrialpackaging.com) - [**](https://www.facebook.com/sharer/sharer.php?u=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput) - [**](https://twitter.com/intent/tweet?text=Doubling+Capacity+%26+Efficiency+without+Doubling+Costs&url=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput&via=) - [**](https://www.linkedin.com/shareArticle?url=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput&title=Doubling+Capacity+%26+Efficiency+without+Doubling+Costs&summary=Optimizing+your+packaging+lines+can+seem+daunting%2C+but+our+team+is+on+point+with+finding+opportunities+for+higher+productivity+greater+efficiencies%21) - [**](mailto:?body=https://www.industrialpackaging.com/blog/tray-line-capacity-throughput) ```json { "@context" : "https://schema.org", "@type" : "BlogPosting", "author" : { "@type" : "Person", "name" : "David Roberge", "url" : "https://www.industrialpackaging.com/blog/author/david-roberge" }, "dateModified" : "2025-12-02T12:44:17.892Z", "datePublished" : "2016-05-19T17:51:23.000Z", "headline" : "Doubling Capacity & Efficiency without Doubling Costs", "image" : [ "//www.industrialpackaging.com/hubfs/Blogging_Images/2016_BLOGGING/tray-line.png" ], "mainEntityOfPage" : { "@id" : "https://www.industrialpackaging.com/blog/tray-line-capacity-throughput", "@type" : "WebPage" }, "publisher" : { "@type" : "Organization", "logo" : { "@type" : "ImageObject", "url" : "https://www.industrialpackaging.com/hubfs/INDUSTRIAL%20PACKAGING%20LOGO%202016.png" }, "name" : "Industrial Packaging" } } ```