Packaging Automation & End-of-Line Systems worked example

Case Erector Capacity at 65% expected case erector uptime: a worked example

This worked example runs the case erector capacity numbers for a tougher week than the baseline: 65% expected case erector uptime instead of the typical 90%. Estimate how many erected and sealed cases a case erector can supply per shift from its forming rate, run time, uptime, and clean-erect quality.

The inputs for this scenario

  • Rated case forming rate: 4 cases / min (held at the documented default)
  • Available case erecting run time: 480 min (held at the documented default)
  • Expected case erector uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Clean-erect first-pass quality: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross erected cases = rated case forming rate × available run time.
  • Good erected cases works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross erected cases works out to 1,920 units at these inputs.
  • Case erector downtime loss works out to 672 units at these inputs.
  • Case 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 case erector 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.
  • 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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Good erected cases: 1,211 units (headline result)
  • Gross erected cases: 1,920 units
  • Case erector downtime loss: 672 units
  • Case reject loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Case Erector Capacity calculator, set expected case erector uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.