Pharmaceutical Packaging & Serialization worked example

Tamper-Evident Seal Cost at 110% seal integrity pass rate: a worked example

What does the result look like when seal integrity pass rate reaches 110%? The full calculation is worked below with real intermediate numbers. A contract packager quoting an OTC bottle batch uses it to size the induction liner and band cost net of seal-integrity rejects.

The inputs for this scenario

  • Units sealed in the run: 50,000 units (unchanged)
  • Seal material cost per unit: 0.09 $/seal (unchanged)
  • Seal integrity pass rate: 110 % (raised for this scenario; the documented default is 99)
  • Sealing line setup and validation cost: 600 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total seal cost = units sealed x seal material cost x integrity pass rate% + line setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 5,275 $ for total tamper-evident seal cost, the number this scenario is built around.
  • At this operating point the engine returns 0.11 $ / piece for tamper-evident seal cost per unit.
  • At this operating point the engine returns 4,675 $ for variable tamper-evident seal cost.
  • At this operating point the engine returns 600 $ for fixed tamper-evident seal cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where seal integrity pass rate sits at 99% and the headline result is 4,808 $, this scenario comes in 9.72% above the baseline at 5,275 $.
  • A figure at this level is achievable when seal integrity pass rate is genuinely sustained, not just peaked for a shift. The formula multiplies material cost by the integrity pass rate as a weighting factor; it does not model the rework or scrap cost of failed seals separately, so treat the pass rate as an effective yield adjustment rather than a full waste model.

Results at a glance

  • Total tamper-evident seal cost: 5,275 $ (headline result)
  • Tamper-evident seal cost per unit: 0.11 $ / piece
  • Variable tamper-evident seal cost: 4,675 $
  • Fixed tamper-evident seal cost adder: 600 $

Run it with your numbers

  • Every input above is editable in the live Tamper-Evident Seal Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.