Grain Milling, Dry Bulk Food & Feed Handling worked example

Pallet Count at 99% palletizing uptime: a worked example

What does the result look like when palletizing uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when warehouse, bagging, or production teams need to know whether palletizing and stretch wrapping can keep up with the bagging line and shipping schedule.

The inputs for this scenario

  • Pallets completed per cycle: 1 pallets / cycle (unchanged)
  • Available palletizing cycles: 180 cycles (unchanged)
  • Palletizing uptime: 99 % (raised for this scenario; the documented default is 90)
  • Accepted pallet yield: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross pallet count = pallets completed per cycle × available palletizing cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 175 pallets for accepted pallet count, the number this scenario is built around.
  • At this operating point the engine returns 180 pallets for gross pallet count.
  • At this operating point the engine returns 1.8 pallets for palletizing downtime loss.
  • At this operating point the engine returns 3.56 pallets for rejected or reworked pallet allowance.

How this compares with the baseline

  • Against the tool's baseline example, where palletizing uptime sits at 90% and the headline result is 159 pallets, this scenario comes in 10% above the baseline at 175 pallets.
  • A figure at this level is achievable when palletizing uptime is genuinely sustained, not just peaked for a shift. It applies uptime and yield as flat factors, so it will not model a single long jam differently from many short stops that sum to the same downtime.

Results at a glance

  • Accepted pallet count: 175 pallets (headline result)
  • Gross pallet count: 180 pallets
  • Palletizing downtime loss: 1.8 pallets
  • Rejected or reworked pallet allowance: 3.56 pallets

Run it with your numbers

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

Last reviewed 2026-05-12.