Bottling, Canning & Filling Lines worked example

Palletizer Capacity at 99% palletizer uptime: a worked example

Push palletizer uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. finished cases need to be checked against palletizer, wrapper, or robot-cell capacity before the run backs up

The inputs for this scenario

  • Cases handled per palletizer cycle: 12 units / cycle (unchanged)
  • Available palletizer cycles per shift: 3,600 cycles (unchanged)
  • Palletizer uptime: 99 % (raised for this scenario; the documented default is 93)
  • First-pass pallet build yield: 99 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross accepted palletizer capacity = cases handled per palletizer cycle × available palletizer cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 42,340 cases for accepted palletizer capacity, the number this scenario is built around.
  • At this operating point the engine returns 43,200 cases for gross accepted palletizer capacity.
  • At this operating point the engine returns 432 cases for accepted palletizer capacity uptime loss.
  • At this operating point the engine returns 428 cases for accepted palletizer capacity quality loss.

How this compares with the baseline

  • Against the tool's baseline example, where palletizer uptime sits at 93% and the headline result is 39,774 cases, this scenario comes in 6.45% above the baseline at 42,340 cases.
  • It computes accepted (good) palletizer capacity in cases by multiplying output per cycle by available cycles, then derating for uptime and first-pass pallet yield. 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

  • Accepted palletizer capacity: 42,340 cases (headline result)
  • Gross accepted palletizer capacity: 43,200 cases
  • Accepted palletizer capacity uptime loss: 432 cases
  • Accepted palletizer capacity quality loss: 428 cases

Run it with your numbers

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

Last reviewed 2026-05-12.