Pet Food & Animal Nutrition Manufacturing worked example

Packaging Cost per Bag at 70% good-bag yield after seal rejects: a worked example

This worked example runs the packaging cost per bag numbers for a tougher week than the baseline: 70% good-bag yield after seal rejects instead of the typical 97%. Estimate the packaging material and setup cost for a kibble or treat bagging run net of QC fallout.

The inputs for this scenario

  • Bags filled per run: 12,000 bags (held at the documented default)
  • Film and bag material cost per bag: 0.42 $/bag (held at the documented default)
  • Good-bag yield after seal rejects: 70 % (the input this scenario stresses; the baseline uses 97)
  • Line changeover and setup charge: 350 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total packaging = bags filled x material cost per bag x good-bag yield% + setup charge.
  • Total packaging cost per bag cost works out to 3,878 $ at these inputs, and this is the headline figure for the scenario.
  • Packaging cost per bag cost per unit works out to 0.32 $ / piece at these inputs.
  • Variable packaging cost per bag cost works out to 3,528 $ at these inputs.
  • Fixed packaging cost per bag adder works out to 350 $ at these inputs.

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 25.98% below the baseline at 3,878 $.
  • Use it when quoting a new bag SKU, comparing bag formats or suppliers, or deciding the minimum economic run length for a changeover. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total packaging cost per bag cost: 3,878 $ (headline result)
  • Packaging cost per bag cost per unit: 0.32 $ / piece
  • Variable packaging cost per bag cost: 3,528 $
  • Fixed packaging cost per bag adder: 350 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Cost per Bag calculator, set good-bag yield after seal rejects to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.