Sterilization & Sterile Barrier Manufacturing worked example

Packaging Scrap Cost at 69% seal-fail reject fraction: a worked example in sterilization & sterile barrier manufacturing

This scenario runs the packaging scrap cost calculation on the strong side: 69% seal-fail reject fraction, with every other input held at its documented default. A packaging engineer uses this to size the dollar exposure of a recurring seal-integrity reject before approving a corrective action.

The inputs for this scenario

  • Pouches scrapped: 1,200 pouches (unchanged)
  • Loaded pouch material cost: 3.85 $/pouch (unchanged)
  • Seal-fail reject fraction: 69 % (raised for this scenario; the documented default is 60)
  • Lot re-qualification fee: 450 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total scrap cost = pouches scrapped x loaded pouch cost x seal-fail % + re-qualification fee) to the inputs above produces each figure below.
  • At this operating point the engine returns 3,638 $ for total packaging scrap cost, the number this scenario is built around.
  • At this operating point the engine returns 3.03 $ / piece for packaging scrap cost per unit.
  • At this operating point the engine returns 3,188 $ for variable packaging scrap cost.
  • At this operating point the engine returns 450 $ for fixed packaging scrap cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where seal-fail reject fraction sits at 60% and the headline result is 3,222 $, this scenario comes in 12.91% above the baseline at 3,638 $.
  • Use it after a seal-integrity event or scrap sweep to quantify the financial hit and decide how aggressively to fix the seal process. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total packaging scrap cost: 3,638 $ (headline result)
  • Packaging scrap cost per unit: 3.03 $ / piece
  • Variable packaging scrap cost: 3,188 $
  • Fixed packaging scrap cost adder: 450 $

Run it with your numbers

  • Every input above is editable in the live Packaging Scrap Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.