Packaging Automation & End-of-Line Systems worked example

Carton Sealer Throughput at 99% expected carton sealer uptime: a worked example

What does the result look like when expected carton sealer uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when you need to confirm a carton sealer can keep up with the packer feeding it.

The inputs for this scenario

  • Rated carton sealing rate: 4 cartons / min (unchanged)
  • Available run time: 480 min (unchanged)
  • Expected carton sealer uptime: 99 % (raised for this scenario; the documented default is 90)
  • Seal quality: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross sealed cartons = rated carton sealing rate × available run time) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good sealed cartons, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross sealed cartons.
  • At this operating point the engine returns 19.2 units for carton sealer downtime loss.
  • At this operating point the engine returns 57.02 units for seal reject loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected carton sealer uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • A figure at this level is achievable when expected carton sealer uptime is genuinely sustained, not just peaked for a shift. It assumes a steady feed of cartons to the sealer; if the upstream filler or erector starves the machine, real throughput drops below this estimate regardless of sealer uptime.

Results at a glance

  • Good sealed cartons: 1,844 units (headline result)
  • Gross sealed cartons: 1,920 units
  • Carton sealer downtime loss: 19.2 units
  • Seal reject loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.