Food & Beverage Manufacturing worked example

Case Packing Rate at 99% case packing efficiency: a worked example

This scenario runs the case packing rate calculation on the strong side: 99% case packing efficiency, with every other input held at its documented default. Use it for manual, semi-automatic, or robotic case packing where carton supply, pack pattern, SKU size, and line balance drive output.

The inputs for this scenario

  • Case packer cycles per hour: 52 cycles / hr (unchanged)
  • Cases completed per cycle: 4 cases / cycle (unchanged)
  • Case packing efficiency: 99 % (raised for this scenario; the documented default is 87)

Working through the calculation

  • Applying the documented formula (Base case packing rate = case packer cycles per hour × cases completed per cycle) to the inputs above produces each figure below.
  • At this operating point the engine returns 206 cases / hr for effective case packing rate, the number this scenario is built around.
  • At this operating point the engine returns 208 cases / hr for base case packing rate.
  • At this operating point the engine returns 2.08 cases / hr for case packing rate loss to inefficiency.
  • At this operating point the engine returns 99 % for case packing efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where case packing efficiency sits at 87% and the headline result is 181 cases / hr, this scenario comes in 13.79% above the baseline at 206 cases / hr.
  • Use it when balancing the case packer against the filler, labeler, and palletizer, or when checking whether a line can clear a daily case target. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Effective case packing rate: 206 cases / hr (headline result)
  • Base case packing rate: 208 cases / hr
  • Case Packing Rate loss to inefficiency: 2.08 cases / hr
  • Case packing efficiency: 99 %

Run it with your numbers

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

Last reviewed 2026-05-12.