Conveyors worked example

Packing Line Capacity at 64% packing line uptime: a worked example

Suppose packing line uptime falls to 64%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Calculate good packs per hour from packing lanes, cycles per lane, uptime, and pack-out yield.

The inputs for this scenario

  • Active packing lanes or stations: 2 lanes (held at the documented default)
  • Pack cycles per lane-hour: 540 packs / lane-hr (held at the documented default)
  • Packing line uptime: 64 % (the input this scenario stresses; the baseline uses 89)
  • Good pack-out yield: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross packing capacity = active lanes × packs per lane-hour.
  • Good packing line capacity works out to 677 packs / hr at these inputs, and this is the headline figure for the scenario.
  • Gross packing capacity works out to 1,080 packs / hr at these inputs.
  • Packing capacity lost to downtime works out to 389 packs / hr at these inputs.
  • Packing capacity lost to rejects works out to 13.82 packs / hr at these inputs.

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 28.09% below the baseline at 677 packs / hr.
  • It computes good packing capacity in packs per hour after derating gross lane capacity for uptime and pack-out yield. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good packing line capacity: 677 packs / hr (headline result)
  • Gross packing capacity: 1,080 packs / hr
  • Packing capacity lost to downtime: 389 packs / hr
  • Packing capacity lost to rejects: 13.82 packs / hr

Run it with your numbers

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

Last reviewed 2026-05-12.