Why does cost per bottle fall as runs get longer?

Setup and labor do not rise with the bottle count, so spreading them over more bottles lowers unit cost. The fixed burden per bottle row shows how much they add at your volume.

What belongs in variable cost per bottle?

Bottle, closure, label and product consumed per filled unit, plus any consumable the line uses per bottle. Costs that appear once per run belong in setup or labor.

Should changeover time be in the run cost?

Changeover minutes are real cost when the line stops, but they belong to the run that pays for the stop. Add them only when this run carries the changeover.

How do I set the target cost per bottle?

Use the standard cost or the quoted price. At the defaults the run costs 1.485 per bottle against a 1.5 target, so it clears with 0.015 per bottle to spare.

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Bottle Filling Run Cost Calculator

Build up a filling run's cost from bottles, variable cost per bottle, setup and labor, then read the cost per bottle. The fixed burden per bottle shows what volume does to unit cost.

What this calculator does

Total run cost and cost per filled bottle from bottles, variable cost, setup and labor, judged against a target.

Formula used

Total filling run cost = bottles to fill × variable cost per bottle + fixed run setup + labor and overhead
Cost per filled bottle = total filling run cost ÷ bottles to fill
Variable cost total = bottles to fill × variable cost per bottle
Fixed and labor per bottle = (fixed run setup + labor and overhead) ÷ bottles to fill
Margin to target per bottle = target cost per bottle − cost per filled bottle

Inputs explained

Bottles to Fill: Bottles scheduled on the filling line for this run.
Variable Cost per Bottle: Bottle, closure, label and product cost for each filled unit.
Fixed Run Setup Cost: Setup charged once for the run, not per bottle.
Labor and Overhead for the Run: Line labor and overhead charged to this run.
Target Cost per Bottle: Unit cost the quote or standard allows.

How to use the result

Best suited to quoting a fill and pack job, choosing between a short and a long run, checking unit cost against a target.
Multi-SKU shifts need shared setup and labor allocated proportionally. Unit cost ignores freight, warehousing and margin.

Common questions

Why does cost per bottle fall as runs get longer? Setup and labor do not rise with the bottle count, so spreading them over more bottles lowers unit cost. The fixed burden per bottle row shows how much they add at your volume.
What belongs in variable cost per bottle? Bottle, closure, label and product consumed per filled unit, plus any consumable the line uses per bottle. Costs that appear once per run belong in setup or labor.
Should changeover time be in the run cost? Changeover minutes are real cost when the line stops, but they belong to the run that pays for the stop. Add them only when this run carries the changeover.
How do I set the target cost per bottle? Use the standard cost or the quoted price. At the defaults the run costs 1.485 per bottle against a 1.5 target, so it clears with 0.015 per bottle to spare.

Last reviewed 2026-10-01.