A system for predicting the performance of a rotary unit operation on a web. The system includes a first rotary roll, a second rotary roll, a nip gap between the first rotary unit and the second rotary roll, a web enabled to travel through the nip, a predetermined pattern, and a computing device comprising a processor and a memory component. The first rotary roll and the second rotary roll are enabled to imprint the predetermined pattern on the web. The memory component stores logic that, when executed by the processor, causes the system to perform at least the following: receive input characteristics of the first rotary roll and the second rotary roll, the web, and the initial nip-gap; receive the predetermined pattern; simulate a transformation performance on the web by the first rotary roll and the second rotary roll; output an analysis demonstrating a load impact factor; and analyze one or more load impact factors to determine if the system will output the predetermined pattern and if the transformation is robust.