Bottling, Canning & Filling Lines worked example

Closure Usage at 71% closure usage transfer efficiency: a worked example

Suppose closure usage transfer efficiency falls to 71%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate crowns, lids, ends, corks, threaded closures, or other closures required for a bottling, canning, or filling run.

The inputs for this scenario

  • Closure Usage covered amount: 60,000 units (held at the documented default)
  • Closure Usage use per unit: 1.01 units (held at the documented default)
  • Closure Usage transfer efficiency: 71 % (the input this scenario stresses; the baseline uses 98.5)

Working through the calculation

  • The calculation starts from the formula this tool documents: Theoretical required closure count = containers scheduled for closures × closures per container including QA allowance.
  • Required closure count works out to 85,775 closures at these inputs, and this is the headline figure for the scenario.
  • Required closure count before yield loss works out to 60,900 closures at these inputs.
  • Required closure count loss allowance works out to 24,875 closures at these inputs.
  • Closure application yield works out to 71 % at these inputs.

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 38.73% above the baseline at 85,775 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Required closure count: 85,775 closures (headline result)
  • Required closure count before yield loss: 60,900 closures
  • Required closure count loss allowance: 24,875 closures
  • Closure application yield: 71 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Closure Usage calculator, set closure usage transfer efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.