Paint, Resin & Polymer Compounding worked example

Drum/tote Fill Throughput at 99% fill line uptime: a worked example

Push fill line uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. you need to know whether the fill line can package the batch on time before committing a ship date

The inputs for this scenario

  • Containers filled per cycle: 1 containers / cycle (unchanged)
  • Available fill cycles: 420 cycles (unchanged)
  • Fill line uptime: 99 % (raised for this scenario; the documented default is 88)
  • First-pass fill yield: 98 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross fill capacity = fills per cycle * available fill cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 407 containers for good fill output, the number this scenario is built around.
  • At this operating point the engine returns 420 containers for gross fill capacity.
  • At this operating point the engine returns 4.2 containers for fill line downtime loss.
  • At this operating point the engine returns 8.32 containers for fill reject loss.

How this compares with the baseline

  • Against the tool's baseline example, where fill line uptime sits at 88% and the headline result is 362 containers, this scenario comes in 12.5% above the baseline at 407 containers.
  • It computes the number of good filled containers after applying fill line uptime and first-pass fill yield to gross fill capacity, and breaks out the downtime and reject losses. 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

  • Good fill output: 407 containers (headline result)
  • Gross fill capacity: 420 containers
  • Fill line downtime loss: 4.2 containers
  • Fill reject loss: 8.32 containers

Run it with your numbers

  • Every input above is editable in the live Drum/tote Fill Throughput calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.