Bottling, Canning & Filling Lines worked example

Throughput Gap with available good line throughput of 2,900 units: a worked example in bottling, canning & filling lines

Suppose available good line throughput falls to 2,900 units. This page works the full calculation at that level so you can see exactly which result moves and by how much. Compare available good packaging throughput with the throughput required to meet the run schedule or customer demand.

The inputs for this scenario

  • Available good line throughput: 2,900 units (the input this scenario stresses; the baseline uses 5,800)
  • Required demand throughput: 6,200 units (held at the documented default)
  • Reference throughput basis: 6,200 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Throughput cushion or shortfall = available good line throughput - required demand throughput.
  • Packaging throughput margin works out to -53.23 % throughput gap at these inputs, and this is the headline figure for the scenario.
  • Throughput shortfall or cushion works out to -3,300 value at these inputs.
  • Available good line throughput works out to 2,900 value at these inputs.
  • Required demand throughput works out to 6,200 value at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where available good line throughput sits at 5,800 units and the headline result is -6.45 % throughput gap, this scenario comes in 725% below the baseline at -53.23 % throughput gap.
  • It computes the difference between available good throughput and required demand, then divides by a reference throughput to express it as a percentage margin. 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

  • Packaging throughput margin: -53.23 % throughput gap (headline result)
  • Throughput shortfall or cushion: -3,300 value
  • Available good line throughput: 2,900 value
  • Required demand throughput: 6,200 value

Run it with your numbers

  • To rerun this with your own numbers, open the live Throughput Gap calculator, set available good line throughput to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.