Bottling, Canning & Filling Lines worked example

Palletizer Capacity at 67% palletizer uptime: a worked example

This worked example runs the palletizer capacity numbers for a tougher week than the baseline: 67% palletizer uptime instead of the typical 93%. Estimate accepted case capacity through a palletizer, robot cell, stretch wrapper, or finished-goods palletizing area.

The inputs for this scenario

  • Cases handled per palletizer cycle: 12 units / cycle (held at the documented default)
  • Available palletizer cycles per shift: 3,600 cycles (held at the documented default)
  • Palletizer uptime: 67 % (the input this scenario stresses; the baseline uses 93)
  • First-pass pallet build yield: 99 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross accepted palletizer capacity = cases handled per palletizer cycle × available palletizer cycles.
  • Accepted palletizer capacity works out to 28,655 cases at these inputs, and this is the headline figure for the scenario.
  • Gross accepted palletizer capacity works out to 43,200 cases at these inputs.
  • Accepted palletizer capacity uptime loss works out to 14,256 cases at these inputs.
  • Accepted palletizer capacity quality loss works out to 289 cases at these inputs.

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 27.96% below the baseline at 28,655 cases.
  • Use it during line balancing, capacity sign-off for a new SKU mix, or when a downstream shipping shortfall suggests the palletizer is the constraint. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Accepted palletizer capacity: 28,655 cases (headline result)
  • Gross accepted palletizer capacity: 43,200 cases
  • Accepted palletizer capacity uptime loss: 14,256 cases
  • Accepted palletizer capacity quality loss: 289 cases

Run it with your numbers

  • To rerun this with your own numbers, open the live Palletizer Capacity calculator, set palletizer uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.