Pet Food & Animal Nutrition Manufacturing worked example

Packaging Cost per Bag at 99% good-bag yield after seal rejects: a worked example

This scenario runs the packaging cost per bag calculation on the strong side: 99% good-bag yield after seal rejects, with every other input held at its documented default. A pet food plant pricing a private-label dry kibble run uses it to see how film cost and seal yield drive the per-bag packaging line of the quote.

The inputs for this scenario

  • Bags filled per run: 12,000 bags (unchanged)
  • Film and bag material cost per bag: 0.42 $/bag (unchanged)
  • Good-bag yield after seal rejects: 99 % (raised for this scenario; the documented default is 97)
  • Line changeover and setup charge: 350 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total packaging = bags filled x material cost per bag x good-bag yield% + setup charge) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,340 $ for total packaging cost per bag cost, the number this scenario is built around.
  • At this operating point the engine returns 0.44 $ / piece for packaging cost per bag cost per unit.
  • At this operating point the engine returns 4,990 $ for variable packaging cost per bag cost.
  • At this operating point the engine returns 350 $ for fixed packaging cost per bag adder.

How this compares with the baseline

  • Against the tool's baseline example, where good-bag yield after seal rejects sits at 97% and the headline result is 5,239 $, this scenario comes in 1.92% above the baseline at 5,340 $.
  • Use it when quoting a new bag SKU, comparing bag formats or suppliers, or deciding the minimum economic run length for a changeover. 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

  • Total packaging cost per bag cost: 5,340 $ (headline result)
  • Packaging cost per bag cost per unit: 0.44 $ / piece
  • Variable packaging cost per bag cost: 4,990 $
  • Fixed packaging cost per bag adder: 350 $

Run it with your numbers

  • Every input above is editable in the live Packaging Cost per Bag calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.