Packaging Automation & End-of-Line Systems worked example

Case Erector Capacity at 99% expected case erector uptime: a worked example

This scenario runs the case erector capacity calculation on the strong side: 99% expected case erector uptime, with every other input held at its documented default. Use it when you need to confirm a case erector can feed the case packer without starving the end of line.

The inputs for this scenario

  • Rated case forming rate: 4 cases / min (unchanged)
  • Available case erecting run time: 480 min (unchanged)
  • Expected case erector uptime: 99 % (raised for this scenario; the documented default is 90)
  • Clean-erect first-pass quality: 97 % (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where expected case erector uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Use it to confirm the erector can supply the case packer, to set shift targets, or to find whether downtime or bad erects limit output. 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 erected cases: 1,844 units (headline result)
  • Gross erected cases: 1,920 units
  • Case erector downtime loss: 19.2 units
  • Case reject loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.