Food & Beverage Manufacturing worked example

Bottling Line Capacity at 60% bottling line availability: a worked example

Suppose bottling line availability falls to 60%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate good bottle output capacity after line availability and first-pass yield losses.

The inputs for this scenario

  • Bottles per filler or packer cycle: 24 bottles / cycle (held at the documented default)
  • Available bottling cycles: 900 cycles (held at the documented default)
  • Bottling line availability: 60 % (the input this scenario stresses; the baseline uses 84)
  • First-pass bottle yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross bottling line capacity = bottles per filler or packer cycle × available bottling cycles.
  • Good bottling line capacity works out to 12,571 bottles at these inputs, and this is the headline figure for the scenario.
  • Gross bottling line capacity works out to 21,600 bottles at these inputs.
  • Bottling Line Capacity downtime loss works out to 8,640 bottles at these inputs.
  • Bottling Line Capacity yield loss works out to 389 bottles at these inputs.

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 28.57% below the baseline at 12,571 bottles.
  • It multiplies bottles per cycle by available cycles for gross capacity, then derates by line availability and first-pass yield to give good bottles. 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

  • Good bottling line capacity: 12,571 bottles (headline result)
  • Gross bottling line capacity: 21,600 bottles
  • Bottling Line Capacity downtime loss: 8,640 bottles
  • Bottling Line Capacity yield loss: 389 bottles

Run it with your numbers

  • To rerun this with your own numbers, open the live Bottling Line Capacity calculator, set bottling line availability to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.