ROI Calculator

Set the sliders to match your operation. Every number is conservative and anchored in PMMI's 2025 packaging industry research.

"Operator training is the biggest impact we have in terms of downtime."
— End user, PMMI Vision 2030 (2025). PMMI found 74% of packaging manufacturers consider knowledge transfer a significant problem, and 59% cite training time vs. production time as their #1 barrier.

Your operation

Number of machines on the floor 10
Unplanned downtime hours per month 50 hrs/mo
Across all machines combined. Typical small-to-mid packaging ops: 20–80 hrs/month total.
Daily output value (revenue when line runs) $25,000
Dollar value of a normal day's production output.
Production hours per day 16 hrs
8 = single shift  ·  16 = two shifts  ·  24 = continuous.
True cost of one downtime hour: $3,125/hr (revenue lost + idle labor + scrap, using the Oxmaint/ABB 2.0× multiplier)

OEM on-site visits

OEM on-site visits per year 2
Visits where a technician travels to your site. Remote/phone support isn't counted here.
Average all-in cost per visit $2,500
Typical: $120–$200/hr × 4–8 hrs, plus travel. Service contracts ($5K–$10K/yr for 2 visits) divide out similarly.

Training & ramp-up

New operators hired per year 2
PMMI 2025: 62% of packaging operators have less than 2 years' experience. Typical turnover drives 1–5 new hires/year for small-mid ops.
Fully-loaded operator hourly wage $35/hr
Wage + benefits + taxes. US packaging operators typically $25–$45/hr fully loaded.
Current ramp-up period 60 days
Industry average: 60–90 days at reduced productivity. Complex lines can run longer.

Your Automated Pack plan

Recommended Tier
Growth — 6–15 machines
$1,195/mo · or $11,950/yr annual prepaid
Content engagement path

+ travel at cost for shoots outside 2hr of Miami. $2,000 scoping visit required and credited on signing.

Payback Period
2.9months
Time for savings to exceed total year-one investment
Year-One ROI
4.2x
Savings vs. total investment (platform + content)
Annual Savings Breakdown
Downtime recovered
45 addressable hrs × $3,125/hr × 40%
$56,250
OEM visits avoided
35% of 2 visits eliminated
$1,750
Faster new-hire ramp
2 hires, 40% faster to full output
$6,720
Total annual savings
$64,720
Year-One Investment
Platform (Growth, annual prepaid)$11,950
Content (Assisted, one-time)$3,500
Total year one$15,450
Net year-one savings
+$49,270
Year 2 and beyond
Only the platform fee recurs. That's a 5.4x return on platform spend, every year after.
Start a 30-day pilot  →

Methodology — Conservative and PMMI-anchored. Hourly downtime cost: (daily revenue ÷ production hours) × 2.0 multiplier for idle labor, scrap, and hidden costs (Oxmaint / ABB methodology). Addressable share: 7.5% of total unplanned downtime — the portion genuinely answerable by an AI knowledge system (excluding parts availability, mechanical failures requiring physical intervention, and process-engineering decisions). Industry research attributes 23% of downtime to human error + knowledge gaps combined (Plant Engineering 2021, ABB Value of Reliability 2024); we apply a conservative fraction of that. Recovery rate: 40% of addressable downtime in year one. OEM savings: 35% visit volume reduction. Ramp savings: wage × 8 hrs/day × ramp days × 50% productivity drag × 40% acceleration.

Industry anchors. 74% of packaging manufacturers consider knowledge transfer a significant problem (PMMI, Knowledge Transfer for Machine Operators, 2025). 59% cite training time vs. production time as the #1 barrier to effective operator training (PMMI, Beyond Manuals, 2025). 62% of operators have less than 2 years' experience (PMMI, 2025). 66% of operators prefer scannable QR codes on machinery as their primary access method (PMMI, 2025). This calculator is a decision aid — actual results are validated during the 30-day pilot.