Fastener Manufacturing & Thread Rolling worked example

Packaging Count Per Box at 99% carton fill efficiency: a worked example

What does the result look like when carton fill efficiency reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when setting box counts, carton labels, case pack sizes, or customer packaging instructions for finished fasteners.

The inputs for this scenario

  • Pieces per inner pack or layer: 250 pieces / pack (unchanged)
  • Inner packs or layers per box: 8 packs (unchanged)
  • Carton fill efficiency: 99 % (raised for this scenario; the documented default is 98)
  • Packaging first-pass yield: 99 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross box count = pieces per inner pack × inner packs per box) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,960 units for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 2,000 pieces for gross intended box count.
  • At this operating point the engine returns 20 pieces for fill efficiency loss.
  • At this operating point the engine returns 19.8 pieces for packaging yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where carton fill efficiency sits at 98% and the headline result is 1,940 units, this scenario comes in 1.02% above the baseline at 1,960 units.
  • A figure at this level is achievable when carton fill efficiency is genuinely sustained, not just peaked for a shift. It assumes one consistent piece-per-pack value; mixed pack sizes or hand-topped cartons won't be captured by these two multipliers.

Results at a glance

  • Good output capacity: 1,960 units (headline result)
  • Gross intended box count: 2,000 pieces
  • Fill efficiency loss: 20 pieces
  • Packaging yield loss: 19.8 pieces

Run it with your numbers

  • Every input above is editable in the live Packaging Count Per Box calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.