Bottling, Canning & Filling Lines worked example

Cap Usage at 99% cap application yield after drops and rejects: a worked example

Push cap application yield after drops and rejects up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a bottling line needs enough caps staged for the run without overissuing inventory to the capper

The inputs for this scenario

  • Bottles scheduled to receive caps: 48,000 units (unchanged)
  • Caps per bottle including samples and startup waste: 1.02 units (unchanged)
  • Cap application yield after drops and rejects: 99 % (raised for this scenario; the documented default is 98)

Working through the calculation

  • Applying the documented formula (Theoretical required cap count = bottles scheduled to receive caps × caps per bottle including samples and startup waste) to the inputs above produces each figure below.
  • At this operating point the engine returns 49,455 caps for required cap count, the number this scenario is built around.
  • At this operating point the engine returns 48,960 caps for required cap count before yield loss.
  • At this operating point the engine returns 495 caps for required cap count loss allowance.
  • At this operating point the engine returns 99 % for cap application yield after drops and rejects.

How this compares with the baseline

  • Against the tool's baseline example, where cap application yield after drops and rejects sits at 98% and the headline result is 49,959 caps, this scenario comes in 1.01% below the baseline at 49,455 caps.
  • It computes the caps required for a run by multiplying bottles by caps per bottle, then dividing by application yield to cover drops and rejects. 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

  • Required cap count: 49,455 caps (headline result)
  • Required cap count before yield loss: 48,960 caps
  • Required cap count loss allowance: 495 caps
  • Cap application yield after drops and rejects: 99 %

Run it with your numbers

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

Last reviewed 2026-05-12.