Industrial Enzymes & Bio-Ingredients worked example

Potency Overfill at 4.32% planned potency overfill: a worked example

This worked example runs the potency overfill numbers for a tougher week than the baseline: 4.32% planned potency overfill instead of the typical 6%. Estimate the cost of potency overfill used to meet guaranteed enzyme activity or bio-ingredient assay claims.

The inputs for this scenario

  • Finished lot active basis: 1,800 kg active (held at the documented default)
  • Cost per active basis unit: 42 $ / kg active (held at the documented default)
  • Planned potency overfill: 4.32 % (the input this scenario stresses; the baseline uses 6)
  • Fixed potency adjustment cost: 1,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable potency overfill cost = finished lot active basis × cost per active basis unit × planned potency overfill.
  • Total potency overfill cost works out to 4,466 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per active basis unit works out to 2.48 $ / kg active at these inputs.
  • Variable potency overfill cost works out to 3,266 $ at these inputs.
  • Fixed potency adjustment cost works out to 1,200 $ at these inputs.

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 22.14% below the baseline at 4,466 $.
  • Use it when setting overfill targets, costing a formulation, or evaluating whether a stability improvement justifies a lower overfill. 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

  • Total potency overfill cost: 4,466 $ (headline result)
  • Cost per active basis unit: 2.48 $ / kg active
  • Variable potency overfill cost: 3,266 $
  • Fixed potency adjustment cost: 1,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Potency Overfill calculator, set planned potency overfill to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.