Printing, Labels & Industrial Converting worked example

Rewind Capacity at 65% rewinder uptime: a worked example

This worked example runs the rewind capacity numbers for a tougher week than the baseline: 65% rewinder uptime instead of the typical 90%. Estimate rewind capacity for printing, labels and industrial converting using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Rolls rewound per cycle: 4 units / cycle (held at the documented default)
  • Available rewind cycles in the window: 480 cycles (held at the documented default)
  • Rewinder uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • Rewind first-pass yield: 97 % (held at the documented default)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where rewinder 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 planning a shift or week of finishing, sizing rewind capacity against order load, or quantifying the cost of downtime and defects. 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 rewind capacity: 1,211 units (headline result)
  • Gross rewind capacity: 1,920 units
  • Rewind capacity downtime loss: 672 units
  • Rewind capacity yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Rewind Capacity calculator, set rewinder uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.