Nutraceuticals & Functional Foods worked example

Capsule Fill Rate at 99% target fill acceptance rate: a worked example

This scenario runs the capsule fill rate calculation on the strong side: 99% target fill acceptance rate, with every other input held at its documented default. An encapsulation operator or QC lead needs to know what percentage of capsules met fill-weight spec during a run and whether the machine is holding target.

The inputs for this scenario

  • Capsules within fill-weight spec: 9,650 capsules (unchanged)
  • Total capsules filled: 10,000 capsules (unchanged)
  • Target fill acceptance rate: 99 % (raised for this scenario; the documented default is 98)

Working through the calculation

  • Applying the documented formula (Capsule fill rate = capsules within fill-weight spec ÷ total capsules filled × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 96.5 % for capsule fill rate, the number this scenario is built around.
  • At this operating point the engine returns 2.5 points for fill rate gap to target.
  • At this operating point the engine returns 9,650 capsules for capsules within fill-weight spec.
  • At this operating point the engine returns 10,000 capsules for total capsules filled.

How this compares with the baseline

  • Against the tool's baseline example, where target fill acceptance rate sits at 98% and the headline result is 96.5 %, this scenario lands almost exactly on the baseline at 96.5 %.
  • Use it at the end of each encapsulation run or at AQL sampling intervals to confirm the line is holding its validated fill window. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Capsule fill rate: 96.5 % (headline result)
  • Fill rate gap to target: 2.5 points
  • Capsules within fill-weight spec: 9,650 capsules
  • Total capsules filled: 10,000 capsules

Run it with your numbers

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

Last reviewed 2026-05-12.