How do you calculate pack-out rate?

Divide containers successfully packed into cases by filled containers available for pack-out, then multiply by 100. With 46,200 packed of 48,000 available, the pack-out rate is 96.25%.

What is a good pack-out rate?

Well-run end-of-line operations target 98-99%+. The 96.25% in this example sits 1.75 points under a 98% target, flagging roughly 840 containers lost between fill and case-pack worth investigating.

What's the difference between pack-out rate and fill efficiency?

Fill efficiency covers losses at the filler; pack-out rate covers losses after filling — case-packer jams, downstream rejects, and damage. A container can fill perfectly and still fail pack-out.

Why are some filled containers not packed out?

Common causes are case-packer or tray-former jams, label/cap QA rejects downstream, dropped or crushed containers, and units pulled for sampling. Each is a different fix even though all lower pack-out.

How do I close the gap to my pack-out target?

Start with the largest loss bucket — usually case-packer faults or a specific reject station. Closing the 1.75-point gap here recovers about 840 containers per 48,000-unit run.

Should sampled or QA-held units count against pack-out?

Decide a convention and stay consistent. If QA pulls are expected and valid, exclude them from available containers so the rate reflects only avoidable loss, not planned sampling.

Bottling, Canning & Filling Lines calculator

Pack-Out Rate Calculator

Pack-Out Rate measures the percentage of filled containers that actually make it into cases or trays at the end of the line, versus how many were available to pack. It's the end-of-line yield metric that catches containers lost to case-packer jams, downstream rejects, recirculation, and damage after filling. Line managers and continuous-improvement teams use it to find where good product is being lost between the filler and the palletizer, and to hold pack-out against a target. A pack-out rate two points under target on a 48,000-container run is roughly 840 containers that were filled, sealed, and then never shipped — pure scrap or rework.

What this calculator does

Measure the percentage of filled containers that make it through cartoning, case packing, tray packing, or finished pack-out.
a packaging team needs to compare packed containers with the filled containers available to case pack or tray pack
It computes the percentage of available filled containers that get packed into cases or trays, and the point gap to your target.

Formula used

Pack-out rate = containers successfully packed into cases or trays ÷ filled containers available for pack-out × 100
Gap to target = target - pack-out rate

Inputs explained

Pack-Out Rate affected amount: undefined
Pack-Out Rate total amount: undefined
Pack-Out Rate target rate: undefined

How to use the result

Use it to monitor end-of-line yield, diagnose case-packer and reject losses, and track pack-out against a goal.
It measures the ratio, not the cause; a low pack-out rate could be case-packer jams, valid QA rejects, or miscounting, so it points you to investigate rather than diagnosing the loss itself.

Common questions

How do you calculate pack-out rate? Divide containers successfully packed into cases by filled containers available for pack-out, then multiply by 100. With 46,200 packed of 48,000 available, the pack-out rate is 96.25%.
What is a good pack-out rate? Well-run end-of-line operations target 98-99%+. The 96.25% in this example sits 1.75 points under a 98% target, flagging roughly 840 containers lost between fill and case-pack worth investigating.
What's the difference between pack-out rate and fill efficiency? Fill efficiency covers losses at the filler; pack-out rate covers losses after filling — case-packer jams, downstream rejects, and damage. A container can fill perfectly and still fail pack-out.
Why are some filled containers not packed out? Common causes are case-packer or tray-former jams, label/cap QA rejects downstream, dropped or crushed containers, and units pulled for sampling. Each is a different fix even though all lower pack-out.
How do I close the gap to my pack-out target? Start with the largest loss bucket — usually case-packer faults or a specific reject station. Closing the 1.75-point gap here recovers about 840 containers per 48,000-unit run.

Last reviewed 2026-05-12.