Printed Electronics & Flexible Hybrid Electronics worked example

Roll-To-Roll Output at 99% line efficiency: a worked example

What does the result look like when line efficiency reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when roll-to-roll output in printed electronics and flexible hybrid electronics is being committed and you need a throughput number you can defend.

The inputs for this scenario

  • Web length or units printed per run: 1,200 units (unchanged)
  • Roll-to-roll run time: 8 hr (unchanged)
  • Line efficiency (uptime x yield): 99 % (raised for this scenario; the documented default is 90)

Working through the calculation

  • Applying the documented formula (Raw roll-to-roll output = completed output รท runtime) to the inputs above produces each figure below.
  • At this operating point the engine returns 149 units / hr for effective throughput, the number this scenario is built around.
  • At this operating point the engine returns 150 units / hr for raw throughput.
  • At this operating point the engine returns 99 % for efficiency.
  • At this operating point the engine returns 8 hr for runtime.

How this compares with the baseline

  • Against the tool's baseline example, where line efficiency sits at 90% and the headline result is 135 units / hr, this scenario comes in 10% above the baseline at 149 units / hr.
  • A figure at this level is achievable when line efficiency is genuinely sustained, not just peaked for a shift. A single efficiency figure blends uptime and yield into one number, so it can mask whether losses come from stoppages or from scrap, which require different fixes.

Results at a glance

  • Effective throughput: 149 units / hr (headline result)
  • Raw throughput: 150 units / hr
  • Efficiency: 99 %
  • Runtime: 8 hr

Run it with your numbers

  • Every input above is editable in the live Roll-To-Roll Output calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.