Aluminum Extrusion & Profile Manufacturing worked example

Extruded Profile Packaging Length Count at 99% packaging station uptime: a worked example

What does the result look like when packaging station uptime reaches 99%? The full calculation is worked below with real intermediate numbers. a shipping or production planner needs to estimate how many feet of profile can be packaged for shipment

The inputs for this scenario

  • Profile length packed per cycle: 480 ft / cycle (unchanged)
  • Available packaging cycles: 18 cycles (unchanged)
  • Packaging station uptime: 99 % (raised for this scenario; the documented default is 90)
  • Accepted packaged-length yield: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross packaged profile length = profile length packed per cycle × available packaging cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 8,383 packaged ft for usable packaged profile length, the number this scenario is built around.
  • At this operating point the engine returns 8,640 packaged ft for gross packaged profile length.
  • At this operating point the engine returns 86.4 packaged ft for length lost to packaging downtime.
  • At this operating point the engine returns 171 packaged ft for length lost to packaging damage or rejects.

How this compares with the baseline

  • Against the tool's baseline example, where packaging station uptime sits at 90% and the headline result is 7,620 packaged ft, this scenario comes in 10% above the baseline at 8,383 packaged ft.
  • A figure at this level is achievable when packaging station uptime is genuinely sustained, not just peaked for a shift. It assumes a constant length per cycle and single uptime and yield figures; mixed bundle sizes or a run of fragile thin-wall profiles can shift actual packed length from the estimate.

Results at a glance

  • Usable packaged profile length: 8,383 packaged ft (headline result)
  • Gross packaged profile length: 8,640 packaged ft
  • Length lost to packaging downtime: 86.4 packaged ft
  • Length lost to packaging damage or rejects: 171 packaged ft

Run it with your numbers

  • Every input above is editable in the live Extruded Profile Packaging Length Count calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.