Bottling, Canning & Filling Lines worked example
Reject Cost at 72% reject cost allocation share: a worked example
This worked example runs the reject cost numbers for a tougher week than the baseline: 72% reject cost allocation share instead of the typical 100%. Estimate the cost of rejects from filling, closing, labeling, inspection, packing, palletizing, or finished-goods containment.
The inputs for this scenario
- Rejected bottles, cans, cases or pallets: 680 units (held at the documented default)
- Average cost per packaging reject: 0.42 $ / unit (held at the documented default)
- Reject cost allocation share: 72 % (the input this scenario stresses; the baseline uses 100)
- Fixed sorting, containment and disposal cost: 900 $ (held at the documented default)
Working through the calculation
- The calculation starts from the formula this tool documents: Allocated filling line reject cost = rejected bottles, cans, cases, or pallets × average cost per packaging reject × allocation share.
- Filling line reject cost works out to 1,106 $ reject cost at these inputs, and this is the headline figure for the scenario.
- Average cost per packaging reject works out to 1.63 $ / reject at these inputs.
- Allocated filling line reject cost works out to 206 $ reject cost at these inputs.
- Fixed sorting, containment, or disposal cost works out to 900 $ at these inputs.
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 6.74% below the baseline at 1,106 $ reject cost.
- Use it during a quality cost review, a scrap-reduction kaizen, or when justifying inspection or fill-control capital. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.
Results at a glance
- Filling line reject cost: 1,106 $ reject cost (headline result)
- Average cost per packaging reject: 1.63 $ / reject
- Allocated filling line reject cost: 206 $ reject cost
- Fixed sorting, containment, or disposal cost: 900 $
Run it with your numbers
- To rerun this with your own numbers, open the live Reject Cost calculator, set reject cost allocation share to your actual value, and adjust the remaining inputs to match your operation.
Last reviewed 2026-05-12.