Glass Container & Bottle Manufacturing worked example

Pack-To-Pallet Throughput at 99% pack-to-pallet uptime: a worked example

This scenario runs the pack-to-pallet throughput calculation on the strong side: 99% pack-to-pallet uptime, with every other input held at its documented default. Use it when the cold end, case packer, palletizer, or warehouse needs to know whether bottles or jars can be packed, palletized, and released fast enough for the forming line and shipping schedule.

The inputs for this scenario

  • Containers packed per pack-to-pallet cycle: 288 containers / cycle (unchanged)
  • Available pack-to-pallet cycles: 120 cycles (unchanged)
  • Pack-to-pallet uptime: 99 % (raised for this scenario; the documented default is 91)
  • Packout first-pass yield: 99 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross pack-to-pallet throughput = containers packed per cycle × available pack-to-pallet cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 33,872 containers for good packed-container throughput, the number this scenario is built around.
  • At this operating point the engine returns 34,560 containers for gross pack-to-pallet throughput.
  • At this operating point the engine returns 346 containers for pack-to-pallet uptime loss.
  • At this operating point the engine returns 342 containers for packout yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where pack-to-pallet uptime sits at 91% and the headline result is 31,135 containers, this scenario comes in 8.79% above the baseline at 33,872 containers.
  • Use it when the palletizer or cartoner is the constraint, or when you need a realistic packed-pallet commitment for a campaign rather than a forming-side gross rate. 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

  • Good packed-container throughput: 33,872 containers (headline result)
  • Gross pack-to-pallet throughput: 34,560 containers
  • Pack-to-pallet uptime loss: 346 containers
  • Packout yield loss: 342 containers

Run it with your numbers

  • Every input above is editable in the live Pack-To-Pallet Throughput calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.