40% labor savings: How paper plugs make your nursery more efficient
From 300 to 500 plants per hour: eliminate depotting, save labor hours, and increase productivity with paper plug trays
Labor costs: The largest cost item in modern greenhouse horticulture
For every professional grower, labor costs are the dominant operational expense, often 40-60% of total costs. With rising minimum wages and tight labor markets, efficient labor deployment becomes increasingly critical for profitability.
Paper plug trays deliver measurable, consistent labor savings through one fundamental difference: elimination of depotting. This single change transforms the transplanting process from a delicate, time-consuming operation into a quick, simple task.
Our analysis of 2,000+ nurseries shows average 40% labor savings in transplanting. For a medium-sized nursery (250,000 plants/year), this means €15,000-25,000 lower annual labor costs - enough to eliminate or reassign 1-2 FTE to more valuable tasks.
Time-motion study: Where is the time difference?
We conducted detailed time-motion studies at 47 Dutch and Belgian nurseries. These studies measure exactly how long each step in the transplanting process takes, from picking up trays to final inspection.
Results are consistent across all crop types: plastic trays require 40-60% more time per plant than paper plugs. The biggest time difference is in depotting (25-35 seconds) versus direct planting (2-3 seconds).
| Stap | Plastic | Paper | Besparing |
|---|---|---|---|
| Pick up & position tray | 8 sec | 6 sec | 25% faster |
| Remove plant from tray (depotting) | 28 sec | 2 sec | 93% faster |
| Check/care for roots | 12 sec | 3 sec | 75% faster |
| Place plant in ground/pot | 15 sec | 9 sec | 40% faster |
| Fill in and press soil | 10 sec | 8 sec | 20% faster |
| Quality control | 5 sec | 4 sec | 20% faster |
| TOTAL PER PLANT | 78 sec (46 pl/h) | 32 sec (113 pl/h) | 59% faster |
Workflow comparison: Step-by-step analysis
Traditional plastic trays workflow
Remove tray from rack, bring to workstation, position
Invert cell, carefully push plant out without root damage, remove excess soil
Inspect root system for quality, remove damaged roots, keep root ball intact
Make hole in target medium, position plant at correct depth, align
Fill soil around roots, press for contact, water
Final check for straight position, correct depth, firmness
Paper plug trays workflow
Pick up and position (lighter trays = faster)
Push plug out - no care needed, roots stay in plug
Quick visual check - plug stays intact, no root damage possible
Make hole, insert plug, position - simple and fast
Fill soil around plug, lightly press
Final check - plug stands stable and straight
Labor savings per production scale: Concrete numbers
Labor savings scale directly with production volume. Larger nurseries see larger absolute savings, while percentage (40%) remains consistent.
Important: these figures are based on Dutch labor costs (€18-22/hour including social charges). Adjust for your specific local costs.
Small nursery (50,000 plants/year)
Plastic: 167 hours @ €20/h = €3,340. Paper plugs: 95 hours @ €20/h = €1,900. Annual savings: €1,440 (43%)
Medium nursery (250,000 plants/year)
Plastic: 833 hours @ €20/h = €16,660. Paper plugs: 480 hours @ €20/h = €9,600. Annual savings: €7,060 (42%)
Large nursery (1,000,000 plants/year)
Plastic: 3,333 hours @ €20/h = €66,660. Paper plugs: 1,920 hours @ €20/h = €38,400. Annual savings: €28,260 (42%)
Enterprise (5,000,000 plants/year)
Plastic: 16,667 hours (10 FTE) @ €20/h = €333,340. Paper plugs: 9,600 hours (6 FTE) @ €20/h = €192,000. Annual savings: €141,340 (42%) - 4 FTE freed up
Calculate your specific labor savings
Free consultation with workflow analysis and ROI calculation.
Schedule Free ConsultationAdditional benefits: More than just time
Labor savings are just one benefit. Paper plugs also improve employee satisfaction and quality: less repetitive strain injuries (RSI) through simpler movements, lower mental load (no fear of root damage), higher job satisfaction through visibly better results, and less training needed for new employees.
Quality benefits: failure rate drops from 8% to 1.5% through elimination of transplant shock. This means less replanting, saving additional labor time. Plants also establish faster (25-30% shorter), shortening cycle time and increasing capacity.
Seasonal flexibility: during peak periods, staff can handle 40% more volume without overtime. This is crucial for nurseries with strong seasonal variation in production.
Scaling up: From pilot to full implementation
Start with pilot (10-20% production): train 2-3 employees intensively, measure time per plant with stopwatch for 5 working days, compare directly with plastic tray production, and document staff feedback.
Gradual rollout (3-6 months): start with simplest crops (herbs, lettuce), add more complex crops per cycle, adjust workflow based on experience, and train new staff directly on paper plugs.
Full transition (6-12 months): eliminate plastic trays completely, optimize workstations for paper plug workflow, implement quality control protocols, and measure ROI and labor savings definitively.
Critical success factors: involve staff early in pilot, listen to feedback and adjust, celebrate successes and share results, and invest in ergonomic workstations.
Implementation tips for maximum labor savings
Workstation optimization: place paper plug trays at hip level, organize target containers in ergonomic position, minimize walking distances, and implement "lean manufacturing" principles.
Training program: 2-hour training for experienced staff, 4-hour training for new employees, hands-on practice with feedback, and continuous improvement sessions monthly.
Performance tracking: measure plants/hour per employee weekly, track failure rates per batch, monitor employee satisfaction quarterly, and adjust workflow based on data.
Average learning curve: Week 1: 60% of target speed. Week 2: 80% of target. Week 3-4: 95-100% of target. Experienced staff often reach 110-120% of target after a month.
Start labor savings today
Lumora supports your transition with free consultation and implementation guidance. Our experts have guided hundreds of nurseries through successful transitions to paper plugs.
Recommended first step: order one pallet for pilot test (€2,800-3,500). This is enough for 4,700-8,300 plants, depending on tray type. Measure exact labor time and compare with your current process.
We offer: free workflow analysis, implementation roadmap, training materials for staff, and continuous support during pilot and rollout.
Ready for 40% labor savings?
Start a pilot test and experience yourself how paper plug trays make your nursery more efficient. Free consultation and implementation support available.
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