Gypsum, Drywall & Interior Panel Manufacturing worked example

Stacker Capacity at 99% stacker uptime: a worked example

This scenario runs the stacker capacity calculation on the strong side: 99% stacker uptime, with every other input held at its documented default. Use it when the board line is increasing speed and you need to confirm the stacker can keep pace without creating a backlog at the end of the dryer.

The inputs for this scenario

  • Boards per stack: 4 boards / stack (unchanged)
  • Stacks per shift: 480 stacks / shift (unchanged)
  • Stacker uptime: 99 % (raised for this scenario; the documented default is 90)
  • Quality yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross stacker output = boards per stack x stacks per shift) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 boards for good output capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 boards for gross capacity.
  • At this operating point the engine returns 19.2 boards for uptime loss.
  • At this operating point the engine returns 57.02 boards for yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where stacker uptime sits at 90% and the headline result is 1,676 boards, this scenario comes in 10% above the baseline at 1,844 boards.
  • Use it when planning shift targets, validating a stacker rate against dryer output, or quantifying how much capacity uptime and reject losses are costing you. 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 output capacity: 1,844 boards (headline result)
  • Gross capacity: 1,920 boards
  • Uptime loss: 19.2 boards
  • Yield loss: 57.02 boards

Run it with your numbers

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

Last reviewed 2026-05-12.