Bottling, Canning & Filling Lines worked example

Reject Cost at 110% reject cost allocation share: a worked example

Push reject cost allocation share up to 110% and the picture changes. This example computes every intermediate figure at that operating point. a bottling, canning, or filling line needs to quantify the financial impact of rejects and containment work

The inputs for this scenario

  • Rejected bottles, cans, cases or pallets: 680 units (unchanged)
  • Average cost per packaging reject: 0.42 $ / unit (unchanged)
  • Reject cost allocation share: 110 % (raised for this scenario; the documented default is 100)
  • Fixed sorting, containment and disposal cost: 900 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Allocated filling line reject cost = rejected bottles, cans, cases, or pallets × average cost per packaging reject × allocation share) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,214 $ reject cost for filling line reject cost, the number this scenario is built around.
  • At this operating point the engine returns 1.79 $ / reject for average cost per packaging reject.
  • At this operating point the engine returns 314 $ reject cost for allocated filling line reject cost.
  • At this operating point the engine returns 900 $ for fixed sorting, containment, or disposal cost.

How this compares with the baseline

  • Against the tool's baseline example, where reject cost allocation share sits at 100% and the headline result is 1,186 $ reject cost, this scenario comes in 2.41% above the baseline at 1,214 $ reject cost.
  • It computes total reject cost by valuing the reject count at an average cost per reject, applying an allocation share, and adding fixed containment and disposal costs. 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

  • Filling line reject cost: 1,214 $ reject cost (headline result)
  • Average cost per packaging reject: 1.79 $ / reject
  • Allocated filling line reject cost: 314 $ reject cost
  • Fixed sorting, containment, or disposal cost: 900 $

Run it with your numbers

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

Last reviewed 2026-05-12.