Capacity planning tool

Convert weekly demand into a practical planning rate.

Enter saleable weekly demand, scheduled production time and headroom. Then test the result against filling, closing, cleaning, changeover, replenishment and operator constraints.

Build a planning route Discuss your application

Average and headroom rateBrief output-band indicationLine-loss warning included

Capacity method

Build from saleable demand backwards

Set weekly demand

Use forecast saleable packs and include product/pack variants.

Define real production time

Remove breaks, cleaning, warm-up, changeovers and maintenance from theoretical hours where appropriate.

Add sensible headroom

Allow growth and normal variation without quoting an unrealistic maximum cycle.

Balance every stage

Compare filler, capper/sealer, labeller, coder, inspection and case-packing constraints.

Prove sustained output

Run representative materials long enough to include replenishment and normal micro-stops.

Important: an integrated line normally needs a detailed capacity model. The calculator is a transparent first pass, not an output guarantee.

Starting bands from the brief

Use weekly bands to shortlist automation level.

These bands frame an initial conversation; they do not prove that a particular machine will achieve the calculated rate.

Fewer than 500/weekDesktop / bench

Manual presentation and semi-automatic filling or closing.

Flexible low-volume route

500–2,000/weekCompact cell

Compact machinery with selected assisted stages.

Structured operator cell

2,000–10,000/weekTwo-head line

Coordinated conveyor filling and downstream operations.

Integrated production

10,000+/weekMulti-head line

Automatic handling and balanced downstream equipment.

Higher sustained demand

Loss model

Account for the time the line is not making accepted packs.

A machine's individual cycle rate is only one part of weekly capacity.

Loss category	Examples	Planning response
Planned non-running	Warm-up, clean-down, format change and scheduled checks.	Deduct time or schedule separate production blocks.
Materials	Product refill, jar loading, closure refill, label-roll and film change.	Model frequency, duration and operator responsibility.
Micro-stops	Missed pack, cap feed interruption, label fault or sensor recovery.	Use representative sustained trials and buffer design.
Quality loss	Start-up waste, rejects, under/overfill and seal faults.	Calculate on accepted packs and improve root causes.
Staffing	Competing tasks, breaks, case packing and material movement.	Create an operator work-content study.
Product variation	Cold batch, higher viscosity, more pieces or foaming.	Qualify the worst credible operating condition.