—
bottles / shift
Required labeler capacity
—BPH
Configuration output
—BPH practical
Matching U-Packer models
| Model | Nameplate | Practical ×η | Verdict |
|---|
Practical = nameplate × your η. “Marginal” fits on paper but depends on hitting η — confirm with factory test data.
Output over time
—
bottles / day
—
bottles / year
Size guard (wrap-around)
Assumptions in this calculation
Methodology — formulas, constants, assumptions
Everything this calculator does is published here so you can verify it. Two directions are supported: from a line requirement to a machine size, and from a rotary configuration to its practical output.
F1 — Theoretical and practical capacity (rotary machines)
Q_theory (BPH) = bottle plates S × turret speed n (rpm) × 60 Q_practical = Q_theory × overall efficiency ηEach bottle plate on the turret labels one container per revolution, so the theoretical output is a pure identity. What separates nameplate from reality is η. Instead of a fixed “fudge factor”, η is built from a time budget:
η = (T_shift − T_loss) ÷ T_shift T_loss = roll changes × time per change + SKU changeovers × time per changeover + glue-system care + unplanned stops| SKU pattern | η preset | What drives it |
|---|---|---|
| Single SKU, long runs | 0.94 | Almost no changeover; roll changes only |
| 2–3 SKUs, occasional changeover | 0.90 | 1–2 changeovers per day |
| Many SKUs, small batches | 0.84 | Frequent changeover + frequent roll changes |
Worked validation example: an 18-plate turret at 12 rpm gives Q_theory = 18 × 12 × 60 = 12,960 BPH; at η = 0.90 the practical output is 11,664 BPH — a 10,000 BPH requirement with 12% headroom (11,200 BPH) is met with margin to spare.
F2 — From required capacity to a model
Q_required = line speed × (1 + headroom), headroom 10–15% recommended Model fits when nameplate BPH × η ≥ Q_requiredThe matching table above is driven by U-Packer nameplate data (station counts and rated BPH from therotary OPP hot melt seriesspecification table and sister models). Models are shown smallest-sufficient first — usually the most economical answer. “Marginal” models meet the requirement at nameplate speed but not at your η; treat them as candidates only if the efficiency assumptions can be improved (fewer SKUs, larger label rolls).
F5 — Size guard for wrap-around labeling
Label length L = π × bottle diameter + overlap (10–15 mm, 12 mm used here) Label height ≤ usable body height − clearanceThe guard flags two hard limits of the standard round-bottle OPP series — label length ≤ 600 mm and label height ≤ 130 mm — plus a handling warning for small-diameter containers at high speed. For the full five-check fit analysis (taper, shrink sleeve), use theBottle & Label Size Checker. Linear machines follow a different capacity identity: Q = conveyor speed (m/min) × 60 ÷ bottle pitch (m).
Constants used
| Constant | Value | Note |
|---|---|---|
| Recommended headroom | 10–15% | Labeler should never be the line bottleneck |
| η presets | 0.94 / 0.90 / 0.84 | Adjustable — replace with your measured η |
| Label overlap | 12 mm | Within the usual 10–15 mm for hot melt wrap-around |
| Standard series label limits | ≤ 600 mm long, ≤ 130 mm high | From the UHL rotary OPP specification table |
Results are indicative engineering estimates, not a quotation. Final sizing is confirmed after we test your bottle and label samples on the actual machine. Glue and material running costs for the configuration you just sized can be estimated with the Hot Melt Glue Cost Calculator.
Frequently asked questions
What does BPH mean, and how do I convert bottles per minute?
BPH is bottles per hour — the standard capacity unit for labeling and filling lines. Multiply bottles per minute (BPM) by 60 to get BPH: a 200 BPM line runs 12,000 BPH. This calculator accepts either unit and always shows both.
Why does my line never reach the machine’s nameplate speed?
Nameplate BPH is theoretical: stations × rpm × 60 with zero stops. Real production loses time to label-roll changes, SKU changeovers, glue-system care and unplanned stops. The overall efficiency η = (shift time − lost time) ÷ shift time typically lands between 0.85 and 0.95 for a single-SKU long run, and nearer 0.80–0.88 for multi-SKU short batches. That is why this tool applies η before matching a model.
How much headroom should I plan above my line speed?
Size the labeler for your upstream/downstream line speed plus 10–15%. The labeler should never be the bottleneck: filler and packer efficiencies differ, and a labeler running permanently at 100% of its nameplate has no reserve for catch-up after a micro-stop.
Does the rotary formula (stations × rpm) apply to linear machines?
No. A linear (in-line) labeler’s theoretical output is Q = conveyor speed v (m/min) × 60 ÷ bottle pitch p (m), where pitch = bottle diameter + minimum gap set by the feed screw or star wheel. Rotary machines dominate above roughly 6,000 BPH; below that, linear and single-station machines are often the economical answer.
How accurate is this calculator?
Indicative, by design. The formulas are exact; the inputs that vary by factory (efficiency η, changeover times) are stated openly and can be adjusted. Final machine sizing is confirmed against your physical bottle and label samples — send us samples and we validate the calculation on the actual machine.