Coatings, Inks & Specialty Chemical Production worked example

Filling Line Throughput at 63% filling line uptime: a worked example in coatings, inks & specialty chemical production

This worked example runs the filling line throughput numbers for a tougher week than the baseline: 63% filling line uptime instead of the typical 88%. Estimate good filled containers from containers per cycle, available filling cycles, line uptime, and first-pass packaging yield.

The inputs for this scenario

  • Containers filled per fill cycle: 24 containers / cycle (held at the documented default)
  • Available fill cycles in the run: 180 cycles (held at the documented default)
  • Filling line uptime (running time fraction): 63 % (the input this scenario stresses; the baseline uses 88)
  • Packaging first-pass yield: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross filling line throughput = containers filled per cycle × available filling cycles.
  • usable filling line throughput works out to 2,667 containers at these inputs, and this is the headline figure for the scenario.
  • gross filling line throughput works out to 4,320 containers at these inputs.
  • filling line throughput lost to downtime works out to 1,598 containers at these inputs.
  • filling line throughput lost to yield works out to 54.43 containers at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where filling line uptime sits at 88% and the headline result is 3,726 containers, this scenario comes in 28.41% below the baseline at 2,667 containers.
  • Use it when you are committing a fill run schedule, comparing two lines, or quantifying how much output a recurring jam or off-weight fill is silently costing you. 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

  • usable filling line throughput: 2,667 containers (headline result)
  • gross filling line throughput: 4,320 containers
  • filling line throughput lost to downtime: 1,598 containers
  • filling line throughput lost to yield: 54.43 containers

Run it with your numbers

  • To rerun this with your own numbers, open the live Filling Line Throughput calculator, set filling line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.