Food & Beverage Manufacturing worked example

Case Packing Rate at 63% case packing efficiency: a worked example

Suppose case packing efficiency falls to 63%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate effective case-packing output from packer cycles, cases per cycle, and expected efficiency.

The inputs for this scenario

  • Case packer cycles per hour: 52 cycles / hr (held at the documented default)
  • Cases completed per cycle: 4 cases / cycle (held at the documented default)
  • Case packing efficiency: 63 % (the input this scenario stresses; the baseline uses 87)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base case packing rate = case packer cycles per hour × cases completed per cycle.
  • Effective case packing rate works out to 131 cases / hr at these inputs, and this is the headline figure for the scenario.
  • Base case packing rate works out to 208 cases / hr at these inputs.
  • Case Packing Rate loss to inefficiency works out to 76.96 cases / hr at these inputs.
  • Case packing efficiency works out to 63 % at these inputs.

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 27.59% below the baseline at 131 cases / hr.
  • It computes effective cases per hour by multiplying packer cycles per hour by cases per cycle and then scaling by case packing efficiency. 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

  • Effective case packing rate: 131 cases / hr (headline result)
  • Base case packing rate: 208 cases / hr
  • Case Packing Rate loss to inefficiency: 76.96 cases / hr
  • Case packing efficiency: 63 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Case Packing Rate calculator, set case packing efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.