Bottling, Canning & Filling Lines worked example

Closure Usage at 99% closure usage transfer efficiency: a worked example

Push closure usage transfer efficiency up to 99% and the picture changes. This example computes every intermediate figure at that operating point. a packaging run needs closure inventory planned from container count, sample allowance, and expected application yield

The inputs for this scenario

  • Closure Usage covered amount: 60,000 units (unchanged)
  • Closure Usage use per unit: 1.01 units (unchanged)
  • Closure Usage transfer efficiency: 99 % (raised for this scenario; the documented default is 98.5)

Working through the calculation

  • Applying the documented formula (Theoretical required closure count = containers scheduled for closures × closures per container including QA allowance) to the inputs above produces each figure below.
  • At this operating point the engine returns 61,515 closures for required closure count, the number this scenario is built around.
  • At this operating point the engine returns 60,900 closures for required closure count before yield loss.
  • At this operating point the engine returns 615 closures for required closure count loss allowance.
  • At this operating point the engine returns 99 % for closure application yield.

How this compares with the baseline

  • Against the tool's baseline example, where closure usage transfer efficiency sits at 98.5% and the headline result is 61,827 closures, this scenario comes in 0.51% below the baseline at 61,515 closures.
  • It computes the total closures to stage by grossing up scheduled containers and per-container usage for QA pulls, then dividing by the capper's application yield to cover spoilage. 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 closure count: 61,515 closures (headline result)
  • Required closure count before yield loss: 60,900 closures
  • Required closure count loss allowance: 615 closures
  • Closure application yield: 99 %

Run it with your numbers

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

Last reviewed 2026-05-12.