Blow Molding & Hollow Plastic Products worked example

Downstream Pack Rate at 99% target downstream pack-through rate: a worked example

Push target downstream pack-through rate up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a blow molding cell needs to check whether downstream packing is matching molded bottle or container output

The inputs for this scenario

  • Containers packed downstream: 39,600 units (unchanged)
  • Containers produced by blow molder: 42,000 units (unchanged)
  • Target downstream pack-through rate: 99 % (raised for this scenario; the documented default is 98)

Working through the calculation

  • Applying the documented formula (Downstream pack-through rate = containers packed downstream ÷ containers produced by blow molder × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 94.29 % packed for downstream pack-through rate, the number this scenario is built around.
  • At this operating point the engine returns 4.71 points for pack rate gap to target.
  • At this operating point the engine returns 39,600 containers for containers packed downstream.
  • At this operating point the engine returns 42,000 containers for containers produced by blow molder.

How this compares with the baseline

  • Against the tool's baseline example, where target downstream pack-through rate sits at 98% and the headline result is 94.29 % packed, this scenario lands almost exactly on the baseline at 94.29 % packed.
  • It computes the percentage of molded containers that reach packing and the gap in points between that rate and your target. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Downstream pack-through rate: 94.29 % packed (headline result)
  • Pack rate gap to target: 4.71 points
  • Containers packed downstream: 39,600 containers
  • Containers produced by blow molder: 42,000 containers

Run it with your numbers

  • Every input above is editable in the live Downstream Pack Rate calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.