Single-Use Bioprocess Assemblies worked example

Leak Test Capacity at 99% leak-test station uptime: a worked example in single-use bioprocess assemblies

Push leak-test station uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when leak test capacity in single-use bioprocess assemblies is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Assemblies tested per leak-test cycle: 4 units / cycle (unchanged)
  • Leak-test cycles available in the period: 480 cycles (unchanged)
  • Leak-test station uptime: 99 % (raised for this scenario; the documented default is 90)
  • Leak-test first-pass yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross leak test capacity = leak test capacity output per cycle × available leak test capacity cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good leak test capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross leak test capacity.
  • At this operating point the engine returns 19.2 units for leak test capacity downtime loss.
  • At this operating point the engine returns 57.02 units for leak test capacity yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where leak-test station uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • It multiplies units per cycle by available cycles for gross capacity, then scales by uptime and first-pass yield to give good tested assemblies. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good leak test capacity: 1,844 units (headline result)
  • Gross leak test capacity: 1,920 units
  • Leak test capacity downtime loss: 19.2 units
  • Leak test capacity yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Leak Test Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.