Industrial Enzymes & Bio-Ingredients worked example

Potency Overfill at 6.9% planned potency overfill: a worked example

Push planned potency overfill up to 6.9% and the picture changes. This example computes every intermediate figure at that operating point. Use it when formulation, quality, and costing teams need to price extra active ingredient added for assay variability or shelf-life decline.

The inputs for this scenario

  • Finished lot active basis: 1,800 kg active (unchanged)
  • Cost per active basis unit: 42 $ / kg active (unchanged)
  • Planned potency overfill: 6.9 % (raised for this scenario; the documented default is 6)
  • Fixed potency adjustment cost: 1,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable potency overfill cost = finished lot active basis × cost per active basis unit × planned potency overfill) to the inputs above produces each figure below.
  • At this operating point the engine returns 6,416 $ for total potency overfill cost, the number this scenario is built around.
  • At this operating point the engine returns 3.56 $ / kg active for cost per active basis unit.
  • At this operating point the engine returns 5,216 $ for variable potency overfill cost.
  • At this operating point the engine returns 1,200 $ for fixed potency adjustment cost.

How this compares with the baseline

  • Against the tool's baseline example, where planned potency overfill sits at 6% and the headline result is 5,736 $, this scenario comes in 11.86% above the baseline at 6,416 $.
  • It computes the variable cost of planned overfill active plus the fixed potency-adjustment cost to give the total cost of guaranteeing label potency. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total potency overfill cost: 6,416 $ (headline result)
  • Cost per active basis unit: 3.56 $ / kg active
  • Variable potency overfill cost: 5,216 $
  • Fixed potency adjustment cost: 1,200 $

Run it with your numbers

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

Last reviewed 2026-05-12.