Conveyors worked example

Packing Line Capacity at 99% packing line uptime: a worked example

What does the result look like when packing line uptime reaches 99%? The full calculation is worked below with real intermediate numbers. a packaging engineer needs to confirm whether packing capacity matches upstream production rate

The inputs for this scenario

  • Active packing lanes or stations: 2 lanes (unchanged)
  • Pack cycles per lane-hour: 540 packs / lane-hr (unchanged)
  • Packing line uptime: 99 % (raised for this scenario; the documented default is 89)
  • Good pack-out yield: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross packing capacity = active lanes × packs per lane-hour) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,048 packs / hr for good packing line capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,080 packs / hr for gross packing capacity.
  • At this operating point the engine returns 10.8 packs / hr for packing capacity lost to downtime.
  • At this operating point the engine returns 21.38 packs / hr for packing capacity lost to rejects.

How this compares with the baseline

  • Against the tool's baseline example, where packing line uptime sits at 89% and the headline result is 942 packs / hr, this scenario comes in 11.24% above the baseline at 1,048 packs / hr.
  • A figure at this level is achievable when packing line uptime is genuinely sustained, not just peaked for a shift. It assumes lanes run independently at a steady rate and doesn't model changeover losses between product or pack formats.

Results at a glance

  • Good packing line capacity: 1,048 packs / hr (headline result)
  • Gross packing capacity: 1,080 packs / hr
  • Packing capacity lost to downtime: 10.8 packs / hr
  • Packing capacity lost to rejects: 21.38 packs / hr

Run it with your numbers

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

Last reviewed 2026-05-12.