Packaging Automation & End-of-Line Systems worked example

Palletizing Cycle Time at 12% pallet change and setup allowance: a worked example

What does the result look like when pallet change and setup allowance reaches 12%? The full calculation is worked below with real intermediate numbers. Use it when you are scheduling palletizing for a run and need a realistic time including pallet changes.

The inputs for this scenario

  • Cases to palletize: 120 cases (unchanged)
  • Palletizing rate: 12 cases / min (unchanged)
  • Pallet change and setup allowance: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

  • Applying the documented formula (Base palletizing time = cases to palletize รท palletizing rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 11.2 hr for planned palletizing time, the number this scenario is built around.
  • At this operating point the engine returns 10 hr for base palletizing time.
  • At this operating point the engine returns 12 % for pallet change and setup allowance.
  • At this operating point the engine returns 12 pieces / min for palletizing rate.

How this compares with the baseline

  • Against the tool's baseline example, where pallet change and setup allowance sits at 10% and the headline result is 11 hr, this scenario comes in 1.82% above the baseline at 11.2 hr.
  • A figure at this level is achievable when pallet change and setup allowance is genuinely sustained, not just peaked for a shift. It assumes a constant stacking rate; full-pallet discharge stalls, layer-pattern complexity and infeed starvation can push actual time beyond the planned figure.

Results at a glance

  • Planned palletizing time: 11.2 hr (headline result)
  • Base palletizing time: 10 hr
  • Pallet change and setup allowance: 12 %
  • Palletizing rate: 12 pieces / min

Run it with your numbers

  • Every input above is editable in the live Palletizing Cycle Time calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.