Packaging & Logistics worked example
Rack Capacity at 99% positions usable: a worked example
What does the result look like when positions usable reaches 99%? The full calculation is worked below with real intermediate numbers. Use it to plan slotting, check if new inventory will fit, and size racking before you commit to more pallet positions.
The inputs for this scenario
- Pallet positions per bay: 21 positions / bay (unchanged)
- Rack bays: 40 bays (unchanged)
- Positions usable: 99 % (raised for this scenario; the documented default is 95)
- Target occupancy: 90 % (unchanged)
Working through the calculation
- Applying the documented formula (Gross rack positions = pallet positions per bay × rack bays) to the inputs above produces each figure below.
- At this operating point the engine returns 748 pallets for usable rack capacity, the number this scenario is built around.
- At this operating point the engine returns 840 pallets for gross rack positions.
- At this operating point the engine returns 8.4 pallets for unusable position loss.
- At this operating point the engine returns 83.16 pallets for honeycomb and occupancy loss.
How this compares with the baseline
- Against the tool's baseline example, where positions usable sits at 95% and the headline result is 718 pallets, this scenario comes in 4.21% above the baseline at 748 pallets.
- A figure at this level is achievable when positions usable is genuinely sustained, not just peaked for a shift. It applies uniform derate factors; it does not model SKU-specific honeycombing where wide or slow-moving items waste far more positions than the average.
Results at a glance
- Usable rack capacity: 748 pallets (headline result)
- Gross rack positions: 840 pallets
- Unusable position loss: 8.4 pallets
- Honeycomb and occupancy loss: 83.16 pallets
Run it with your numbers
- Every input above is editable in the live Rack Capacity calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.