Packaging Automation & End-of-Line Systems worked example

Pallet Pattern Efficiency at 99% target pattern efficiency: a worked example

What does the result look like when target pattern efficiency reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when you are reviewing a pallet pattern and want to know how much deck space is being left on the table.

The inputs for this scenario

  • Cases placed per pallet: 48 cases (unchanged)
  • Maximum cases the footprint allows: 50 cases (unchanged)
  • Target pattern efficiency: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Pallet pattern efficiency = cases placed per pallet ÷ maximum cases the footprint allows × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 96 % for pallet pattern efficiency, the number this scenario is built around.
  • At this operating point the engine returns 3 points for gap to efficiency target.
  • At this operating point the engine returns 48 count for cases placed per pallet.
  • At this operating point the engine returns 50 count for maximum cases the footprint allows.

How this compares with the baseline

  • Against the tool's baseline example, where target pattern efficiency sits at 95% and the headline result is 96 %, this scenario lands almost exactly on the baseline at 96 %.
  • A figure at this level is achievable when target pattern efficiency is genuinely sustained, not just peaked for a shift. It measures area/case utilization on a single layer logic basis and does not account for load stability, overhang penalties from the receiver, or weight limits that may cap stack height before the footprint fills.

Results at a glance

  • Pallet pattern efficiency: 96 % (headline result)
  • Gap to efficiency target: 3 points
  • Cases placed per pallet: 48 count
  • Maximum cases the footprint allows: 50 count

Run it with your numbers

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

Last reviewed 2026-05-12.