How do you calculate blister pack yield?

Divide the defect count by the total packs produced and multiply by 100. With 8 rejects out of 250 packs that is 8 ÷ 250 × 100 = 3.2%. To express good yield instead, subtract from 100 for 96.8%.

Is 3.2% a good blister reject rate?

For a mature pharma blister line, in-process reject rates are typically well under 1-2%, so 3.2% would warrant a look at the sealing station, foil lot or feed system. The right benchmark depends on product and platform.

What does the gap to target of 91.8 points mean here?

It is the reject rate of 3.2% minus the 95% figure entered as target, which produces a large negative-direction number. Because this preset compares against the entered target literally, set your target as a reject target (e.g. 2%) for a meaningful gap.

Reject rate vs yield — what is the difference?

Reject rate is defects over total (3.2% here); good yield is 100 minus reject rate (96.8%). They describe the same run from opposite ends; pick one convention and label it clearly on reports.

What causes blister pack defects?

Common drivers are inadequate seal temperature or pressure, foil pinholes and coating flaws, forming-web issues, tablet feed misfeeds and camera-detected missing or broken tablets. Trend the rate to isolate which station is drifting.

Should I count camera rejects in this number?

Yes, if they represent real defective packs removed from the batch. Be consistent: decide up front whether validation-station ejects and false rejects are included, so run-to-run comparisons stay honest.

Pharmaceutical Packaging & Serialization calculator

Blister pack yield Calculator

Blister Pack Yield here expresses the share of blister packs flagged as rejects or defects against the total produced, and the gap between that rate and your target. It matters because blister thermoforming and sealing defects — short fills, seal leaks, foil pinholes, missing tablets caught by camera — directly drive material scrap and can trigger batch investigations. Packaging engineers, line QA and continuous-improvement teams watch this per run to catch a drifting sealing station or a bad foil lot before it consumes a batch. On high-speed platforms running 400+ blisters a minute, a fraction of a percent is a lot of destroyed product.

What this calculator does

Estimate blister pack yield for pharmaceutical packaging and serialization using production-ready inputs so teams can track KPI performance and decide whether corrective action is needed.
Use it when blister pack yield in pharmaceutical packaging and serialization needs a clean rate and gap-to-target you can put on a tier board.
It computes what percentage of the total blisters produced fell into the reject/defect count, and how far that percentage sits from your target rate.

Formula used

Blister pack yield rate = blister pack yield count ÷ total blister pack yield population × 100
Blister pack yield gap to target = blister pack yield rate - target blister pack yield rate

Inputs explained

Rejected or defective blister packs:
Total blister packs produced in the run:
Target defect (reject) rate:

How to use the result

Use it at run close-out or in-process to track blister reject rate against a target and to flag runs that need investigation.
With this field mapping the output is a reject rate, not a good-yield rate — a low number is good and a high number is bad, which is the opposite of a typical yield reading, so read the sign of the gap carefully.

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.
U.S. manufacturing runs at 75.6% of capacity with new factory orders at $657B per month (Federal Reserve and Census, May 2026).

Common questions

How do you calculate blister pack yield? Divide the defect count by the total packs produced and multiply by 100. With 8 rejects out of 250 packs that is 8 ÷ 250 × 100 = 3.2%. To express good yield instead, subtract from 100 for 96.8%.
Is 3.2% a good blister reject rate? For a mature pharma blister line, in-process reject rates are typically well under 1-2%, so 3.2% would warrant a look at the sealing station, foil lot or feed system. The right benchmark depends on product and platform.
What does the gap to target of 91.8 points mean here? It is the reject rate of 3.2% minus the 95% figure entered as target, which produces a large negative-direction number. Because this preset compares against the entered target literally, set your target as a reject target (e.g. 2%) for a meaningful gap.
Reject rate vs yield — what is the difference? Reject rate is defects over total (3.2% here); good yield is 100 minus reject rate (96.8%). They describe the same run from opposite ends; pick one convention and label it clearly on reports.
What causes blister pack defects? Common drivers are inadequate seal temperature or pressure, foil pinholes and coating flaws, forming-web issues, tablet feed misfeeds and camera-detected missing or broken tablets. Trend the rate to isolate which station is drifting.

Last reviewed 2026-05-12.