Nutraceuticals & Functional Foods worked example

Ingredient Potency Overfill at 7.2% potency overage above claim: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop potency overage above claim to 7.2%, then walk the calculation through step by step. Estimate the cost of active ingredient overage added to hold label claim across shelf life, so formulation and cost teams can price potency overfill per batch.

The inputs for this scenario

  • Active ingredient per batch: 12 kg (held at the documented default)
  • Active ingredient cost: 180 $ / kg (held at the documented default)
  • Potency overage above claim: 7.2 % (the input this scenario stresses; the baseline uses 10)
  • Fixed assay and stability cost: 300 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Overage material cost = active ingredient per batch × active ingredient cost × potency overage above claim.
  • Total overage cost works out to 456 $ at these inputs, and this is the headline figure for the scenario.
  • Overage cost per kg of active works out to 37.96 $ / kg at these inputs.
  • Overage material cost works out to 156 $ at these inputs.
  • Fixed assay and stability cost works out to 300 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where potency overage above claim sits at 10% and the headline result is 516 $, this scenario comes in 11.72% below the baseline at 456 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to potency overage above claim, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a single flat overage percentage and does not model degradation curves, so it will not tell you the minimum scientifically justified overage.

Results at a glance

  • Total overage cost: 456 $ (headline result)
  • Overage cost per kg of active: 37.96 $ / kg
  • Overage material cost: 156 $
  • Fixed assay and stability cost: 300 $

Run it with your numbers

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

Last reviewed 2026-05-12.