Blow Molding & Hollow Plastic Products worked example

Leak Test Capacity at 68% leak tester uptime: a worked example in blow molding & hollow plastic products

Here is what the math looks like when conditions slip. We hold every other input steady and drop leak tester uptime to 68%, then walk the calculation through step by step. Estimate accepted leak-tested bottle, container, drum, or tank output from test heads per cycle, available cycles, tester uptime, and first-pass leak yield.

The inputs for this scenario

  • Containers tested per leak-test cycle: 4 units / cycle (held at the documented default)
  • Available leak-test cycles: 1,800 cycles (held at the documented default)
  • Leak tester uptime: 68 % (the input this scenario stresses; the baseline uses 94)
  • First-pass leak-test yield: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross leak-test slots = containers tested per cycle × available leak-test cycles.
  • Accepted leak-test capacity works out to 4,798 containers at these inputs, and this is the headline figure for the scenario.
  • Gross leak-test slots works out to 7,200 containers at these inputs.
  • Leak-test downtime loss works out to 2,304 containers at these inputs.
  • Leak-test reject and retest loss works out to 97.92 containers at these inputs.

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 27.66% below the baseline at 4,798 containers.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to leak tester uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes uptime and yield are independent and constant; in reality a struggling tester often loses uptime and yield together, and retest loops can recover some rejected units it does not credit.

Results at a glance

  • Accepted leak-test capacity: 4,798 containers (headline result)
  • Gross leak-test slots: 7,200 containers
  • Leak-test downtime loss: 2,304 containers
  • Leak-test reject and retest loss: 97.92 containers

Run it with your numbers

  • To rerun this with your own numbers, open the live Leak Test Capacity calculator, set leak tester uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.