Packaging Automation & End-of-Line Systems worked example

Pallet Pattern Efficiency at 68% target pattern efficiency: a worked example

Suppose target pattern efficiency falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Calculate how well a pallet pattern uses the deck by comparing cases actually placed against the cases the footprint could hold.

The inputs for this scenario

  • Cases placed per pallet: 48 cases (held at the documented default)
  • Maximum cases the footprint allows: 50 cases (held at the documented default)
  • Target pattern efficiency: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Pallet pattern efficiency = cases placed per pallet ÷ maximum cases the footprint allows × 100.
  • Pallet pattern efficiency works out to 96 % at these inputs, and this is the headline figure for the scenario.
  • Gap to efficiency target works out to -28 points at these inputs.
  • Cases placed per pallet works out to 48 count at these inputs.
  • Maximum cases the footprint allows works out to 50 count at these inputs.

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 %.
  • It computes the percentage of the pallet's case-capacity footprint that your current stacking pattern actually fills, plus the point gap to your efficiency target. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Pallet pattern efficiency: 96 % (headline result)
  • Gap to efficiency target: -28 points
  • Cases placed per pallet: 48 count
  • Maximum cases the footprint allows: 50 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Pallet Pattern Efficiency calculator, set target pattern efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.