With's Del's recipe (1/2 cup salt, 1/4 cup softener to 1 cup plastic) I can pour 30 t-sticks. So, that comes out to 480 t-sticks per gallon if my math is right. I pour mine with pyrex so I don't know about the production pot.
Alphaone -- I'm using the recipe that I referenced above. I believe that's Del's standard formula. Are you pouring the thicker T-stick like I am, or the thinner senko type? My t-sticks seem a bit tight to me, but I had a guy giving them a good workout today and I'm just waiting to hear. I feel like I could go a tad bit softer with them, however. As far as durablility, my sticks should stand up to quite a few fish before they need changed but we'll see..