Pharmaceutical Packaging & Serialization worked example

Cartoner Throughput at 99% expected cartoner uptime: a worked example

This scenario runs the cartoner throughput calculation on the strong side: 99% expected cartoner uptime, with every other input held at its documented default. Use it when cartoner throughput in pharmaceutical packaging and serialization is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Cartons formed per machine cycle: 4 units / cycle (unchanged)
  • Available cartoner cycles in the run: 480 cycles (unchanged)
  • Expected cartoner uptime: 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass carton yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross cartoner throughput capacity = cartoner throughput output per cycle × available cartoner throughput cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good cartoner throughput capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross cartoner throughput capacity.
  • At this operating point the engine returns 19.2 units for cartoner throughput downtime loss.
  • At this operating point the engine returns 57.02 units for cartoner throughput yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where expected cartoner uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Use it when setting shift production targets, sizing a run against a delivery deadline, or diagnosing whether throughput loss is a downtime or a quality problem. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good cartoner throughput capacity: 1,844 units (headline result)
  • Gross cartoner throughput capacity: 1,920 units
  • Cartoner throughput downtime loss: 19.2 units
  • Cartoner throughput yield loss: 57.02 units

Run it with your numbers

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

Last reviewed 2026-05-12.