Grain Milling, Dry Bulk Food & Feed Handling worked example

Pallet Count at 65% palletizing uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop palletizing uptime to 65%, then walk the calculation through step by step. Estimate good pallet output for bagged grain, flour, feed, meal, pellets, or dry ingredients using pallets per cycle, available cycles, palletizing uptime, and accepted pallet yield.

The inputs for this scenario

  • Pallets completed per cycle: 1 pallets / cycle (held at the documented default)
  • Available palletizing cycles: 180 cycles (held at the documented default)
  • Palletizing uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Accepted pallet yield: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross pallet count = pallets completed per cycle × available palletizing cycles.
  • Accepted pallet count works out to 115 pallets at these inputs, and this is the headline figure for the scenario.
  • Gross pallet count works out to 180 pallets at these inputs.
  • Palletizing downtime loss works out to 63 pallets at these inputs.
  • Rejected or reworked pallet allowance works out to 2.34 pallets at these inputs.

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 27.78% below the baseline at 115 pallets.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to palletizing uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 115 pallets (headline result)
  • Gross pallet count: 180 pallets
  • Palletizing downtime loss: 63 pallets
  • Rejected or reworked pallet allowance: 2.34 pallets

Run it with your numbers

  • To rerun this with your own numbers, open the live Pallet Count calculator, set palletizing uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.