Food & Beverage Manufacturing worked example

Bottling Line Capacity at 97% bottling line availability: a worked example

What does the result look like when bottling line availability reaches 97%? The full calculation is worked below with real intermediate numbers. Use it for beverage, sauce, oil, dressing, supplement, personal care, or CPG bottling lines that need shift, day, or campaign capacity.

The inputs for this scenario

  • Bottles per filler or packer cycle: 24 bottles / cycle (unchanged)
  • Available bottling cycles: 900 cycles (unchanged)
  • Bottling line availability: 97 % (raised for this scenario; the documented default is 84)
  • First-pass bottle yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross bottling line capacity = bottles per filler or packer cycle × available bottling cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 20,323 bottles for good bottling line capacity, the number this scenario is built around.
  • At this operating point the engine returns 21,600 bottles for gross bottling line capacity.
  • At this operating point the engine returns 648 bottles for bottling line capacity downtime loss.
  • At this operating point the engine returns 629 bottles for bottling line capacity yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where bottling line availability sits at 84% and the headline result is 17,600 bottles, this scenario comes in 15.48% above the baseline at 20,323 bottles.
  • A figure at this level is achievable when bottling line availability is genuinely sustained, not just peaked for a shift. It treats availability and yield as fixed percentages; in reality both vary by SKU and shift, so a single average can hide a problem SKU that drags the real number down.

Results at a glance

  • Good bottling line capacity: 20,323 bottles (headline result)
  • Gross bottling line capacity: 21,600 bottles
  • Bottling Line Capacity downtime loss: 648 bottles
  • Bottling Line Capacity yield loss: 629 bottles

Run it with your numbers

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

Last reviewed 2026-05-12.