Bottling, Canning & Filling Lines worked example

Fill Rate at 99% fill rate target for the run: a worked example

What does the result look like when fill rate target for the run reaches 99%? The full calculation is worked below with real intermediate numbers. a filling line team needs to know whether actual filled bottles, cans, or jars are keeping pace with the scheduled run quantity

The inputs for this scenario

  • Filled bottles or cans released by the filler: 47,500 units (unchanged)
  • Scheduled bottles or cans for the same run window: 50,000 units (unchanged)
  • Fill rate target for the run: 99 % (raised for this scenario; the documented default is 96)

Working through the calculation

  • Applying the documented formula (Fill rate = filled bottles or cans released by the filler ÷ scheduled bottles or cans for the same run window × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 95 % fill rate for fill rate, the number this scenario is built around.
  • At this operating point the engine returns 4 points for fill rate gap to target.
  • At this operating point the engine returns 47,500 count for filled bottles or cans released by the filler.
  • At this operating point the engine returns 50,000 count for scheduled bottles or cans for the same run window.

How this compares with the baseline

  • Against the tool's baseline example, where fill rate target for the run sits at 96% and the headline result is 95 % fill rate, this scenario lands almost exactly on the baseline at 95 % fill rate.
  • A figure at this level is achievable when fill rate target for the run is genuinely sustained, not just peaked for a shift. Fill rate counts output against schedule, not against rated line speed, so a line can hit 95% fill rate while running well under its mechanical capacity if the schedule was set conservatively.

Results at a glance

  • Fill rate: 95 % fill rate (headline result)
  • Fill rate gap to target: 4 points
  • Filled bottles or cans released by the filler: 47,500 count
  • Scheduled bottles or cans for the same run window: 50,000 count

Run it with your numbers

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

Last reviewed 2026-05-12.