Fastener Manufacturing & Thread Rolling worked example

Packaging Count Per Box at 71% carton fill efficiency: a worked example

Suppose carton fill efficiency falls to 71%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate shippable fasteners per carton from pieces per inner pack, packs per box, fill efficiency, and packaging yield.

The inputs for this scenario

  • Pieces per inner pack or layer: 250 pieces / pack (held at the documented default)
  • Inner packs or layers per box: 8 packs (held at the documented default)
  • Carton fill efficiency: 71 % (the input this scenario stresses; the baseline uses 98)
  • Packaging first-pass yield: 99 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross box count = pieces per inner pack × inner packs per box.
  • Good output capacity works out to 1,406 units at these inputs, and this is the headline figure for the scenario.
  • Gross intended box count works out to 2,000 pieces at these inputs.
  • Fill efficiency loss works out to 580 pieces at these inputs.
  • Packaging yield loss works out to 14.2 pieces at these inputs.

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 27.55% below the baseline at 1,406 units.
  • It computes the shippable fastener count per carton after applying fill efficiency and packaging yield to the intended pieces-per-pack times packs-per-box. 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 output capacity: 1,406 units (headline result)
  • Gross intended box count: 2,000 pieces
  • Fill efficiency loss: 580 pieces
  • Packaging yield loss: 14.2 pieces

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Count Per Box calculator, set carton fill efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.