Packaging Automation & End-of-Line Systems worked example

Carton Sealer Throughput at 65% expected carton sealer uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected carton sealer uptime to 65%, then walk the calculation through step by step. Estimate the good sealed cartons a carton sealer can deliver per shift from its sealing rate, run time, uptime, and seal quality.

The inputs for this scenario

  • Rated carton sealing rate: 4 cartons / min (held at the documented default)
  • Available run time: 480 min (held at the documented default)
  • Expected carton sealer uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Seal quality: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross sealed cartons = rated carton sealing rate × available run time.
  • Good sealed cartons works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross sealed cartons works out to 1,920 units at these inputs.
  • Carton sealer downtime loss works out to 672 units at these inputs.
  • Seal reject loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected carton sealer uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 1,211 units (headline result)
  • Gross sealed cartons: 1,920 units
  • Carton sealer downtime loss: 672 units
  • Seal reject loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Carton Sealer Throughput calculator, set expected carton sealer uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.