Blow Molding & Hollow Plastic Products worked example

Leak Test Capacity at 99% leak tester uptime: a worked example in blow molding & hollow plastic products

Push leak tester uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a blow molding cell needs to confirm leak-test throughput before committing production or shipping volume

The inputs for this scenario

  • Containers tested per leak-test cycle: 4 units / cycle (unchanged)
  • Available leak-test cycles: 1,800 cycles (unchanged)
  • Leak tester uptime: 99 % (raised for this scenario; the documented default is 94)
  • First-pass leak-test yield: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross leak-test slots = containers tested per cycle × available leak-test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 6,985 containers for accepted leak-test capacity, the number this scenario is built around.
  • At this operating point the engine returns 7,200 containers for gross leak-test slots.
  • At this operating point the engine returns 72 containers for leak-test downtime loss.
  • At this operating point the engine returns 143 containers for leak-test reject and retest loss.

How this compares with the baseline

  • Against the tool's baseline example, where leak tester uptime sits at 94% and the headline result is 6,633 containers, this scenario comes in 5.32% above the baseline at 6,985 containers.
  • It multiplies containers per cycle by available cycles to get gross slots, then derates by leak tester uptime and first-pass yield to give accepted container capacity, and itemizes the downtime and reject losses. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Accepted leak-test capacity: 6,985 containers (headline result)
  • Gross leak-test slots: 7,200 containers
  • Leak-test downtime loss: 72 containers
  • Leak-test reject and retest loss: 143 containers

Run it with your numbers

  • Every input above is editable in the live Leak Test Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.