Pharmaceutical Packaging & Serialization worked example

Cartoner Throughput at 65% expected cartoner uptime: a worked example

This worked example runs the cartoner throughput numbers for a tougher week than the baseline: 65% expected cartoner uptime instead of the typical 90%. Estimate cartoner throughput for pharmaceutical packaging and serialization using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Cartons formed per machine cycle: 4 units / cycle (held at the documented default)
  • Available cartoner cycles in the run: 480 cycles (held at the documented default)
  • Expected cartoner uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected first-pass carton yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross cartoner throughput capacity = cartoner throughput output per cycle × available cartoner throughput cycles.
  • Good cartoner throughput capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross cartoner throughput capacity works out to 1,920 units at these inputs.
  • Cartoner throughput downtime loss works out to 672 units at these inputs.
  • Cartoner throughput yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Good cartoner throughput capacity: 1,211 units (headline result)
  • Gross cartoner throughput capacity: 1,920 units
  • Cartoner throughput downtime loss: 672 units
  • Cartoner throughput yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Cartoner Throughput calculator, set expected cartoner uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.