Pharmaceutical Packaging & Serialization worked example

Tamper-Evident Seal Cost at 71% seal integrity pass rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop seal integrity pass rate to 71%, then walk the calculation through step by step. Estimate the tamper-evident sealing cost for a pharmaceutical bottling or cartoning batch including integrity fallout.

The inputs for this scenario

  • Units sealed in the run: 50,000 units (held at the documented default)
  • Seal material cost per unit: 0.09 $/seal (held at the documented default)
  • Seal integrity pass rate: 71 % (the input this scenario stresses; the baseline uses 99)
  • Sealing line setup and validation cost: 600 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total seal cost = units sealed x seal material cost x integrity pass rate% + line setup.
  • Total tamper-evident seal cost works out to 3,618 $ at these inputs, and this is the headline figure for the scenario.
  • Tamper-evident seal cost per unit works out to 0.07 $ / piece at these inputs.
  • Variable tamper-evident seal cost works out to 3,018 $ at these inputs.
  • Fixed tamper-evident seal cost adder works out to 600 $ at these inputs.

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 24.75% below the baseline at 3,618 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to seal integrity pass rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 3,618 $ (headline result)
  • Tamper-evident seal cost per unit: 0.07 $ / piece
  • Variable tamper-evident seal cost: 3,018 $
  • Fixed tamper-evident seal cost adder: 600 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Tamper-Evident Seal Cost calculator, set seal integrity pass rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.