How do you calculate checkweigher reject cost?

Multiply rejected packs by value per pack by the scrap share to get variable cost, then add fixed recheck and disposal cost. For 100 packs at $45, 80% scrapped, plus $250 fixed, total cost is $3,850.

What is the cost per rejected pack?

Divide total reject cost by the number of rejected packs. In the worked example $3,850 across 100 packs is $38.50 per pack — higher than the $45 product value times 80% because the fixed $250 is spread across the rejects.

Why include a fixed recheck and disposal cost?

Rejected packs do not vanish — someone reweighs, sorts, and disposes of them, and waste hauling has a baseline charge. The $250 fixed cost captures that overhead independent of how many packs failed.

How does the scrap share change the cost?

It is the fraction of rejects that cannot be reworked. At 80% scrap the variable cost is $3,600; if you could rework half of them and drop scrap share to 40%, variable cost would halve to $1,800.

What is a good checkweigher reject rate?

On a well-controlled filling line, reject rates typically run well under 1% of packs. The dollar figure matters more than the count — 100 high-value rejects at $38.50 each is $3,850 of avoidable loss per period.

How do I reduce checkweigher reject cost?

Tighten filler target weight control to cut the reject count, and set up rework so fewer rejects are scrapped. Lowering scrap share is often the fastest lever since it directly shrinks the $3,600 variable component.

Packaging Automation & End-of-Line Systems calculator

Checkweigher Reject Cost Calculator

Checkweigher reject cost is the money lost when packs fail the in-line weight check and are pushed off the line as underweight, overweight, or unstable. Quality managers and packaging cost engineers track it because every rejected pack carries both the value of the product inside and a slice of handling, recheck, and disposal overhead. A checkweigher protects you from giving away product and from regulatory underfill penalties, but each rejection still costs real money. Quantifying that cost tells you whether to invest in filler accuracy, rework lines, or tighter weight control upstream.

What this calculator does

Estimate the cost of packs rejected at the checkweigher from reject count, value per rejected pack, scrap share, and fixed recheck cost.
Use it when checkweigher rejects are climbing and you need to size the dollar impact before chasing the root cause.
It computes the total cost of checkweigher rejects by combining the scrapped value of rejected packs with fixed recheck and disposal overhead.

Formula used

Variable reject cost = packs rejected × value per rejected pack × share scrapped not reworked
Total checkweigher reject cost = variable reject cost + fixed recheck and disposal cost

Inputs explained

Packs rejected:
Value per rejected pack:
Share scrapped not reworked:
Fixed recheck and disposal cost:

How to use the result

Use it when a reject spike hits, when justifying a filler upgrade, or when building the quality cost section of a line's monthly report.
It treats the scrap share as outright loss; if rejected product can be reclaimed, reblended, or sold as seconds, the true net cost is lower than shown.

Current U.S. benchmarks

The producer price index for plastic resins and materials stands at 319.371 (BLS, May 2026), up 19.5% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for paperboard and containers stands at 276.831 (BLS, May 2026), up 8.8% from a year earlier. Quotes priced off last quarter's material cost miss this move.

Common questions

How do you calculate checkweigher reject cost? Multiply rejected packs by value per pack by the scrap share to get variable cost, then add fixed recheck and disposal cost. For 100 packs at $45, 80% scrapped, plus $250 fixed, total cost is $3,850.
What is the cost per rejected pack? Divide total reject cost by the number of rejected packs. In the worked example $3,850 across 100 packs is $38.50 per pack — higher than the $45 product value times 80% because the fixed $250 is spread across the rejects.
Why include a fixed recheck and disposal cost? Rejected packs do not vanish — someone reweighs, sorts, and disposes of them, and waste hauling has a baseline charge. The $250 fixed cost captures that overhead independent of how many packs failed.
How does the scrap share change the cost? It is the fraction of rejects that cannot be reworked. At 80% scrap the variable cost is $3,600; if you could rework half of them and drop scrap share to 40%, variable cost would halve to $1,800.
What is a good checkweigher reject rate? On a well-controlled filling line, reject rates typically run well under 1% of packs. The dollar figure matters more than the count — 100 high-value rejects at $38.50 each is $3,850 of avoidable loss per period.

Last reviewed 2026-05-12.