Sterilization & Sterile Barrier Manufacturing worked example

Packaging Scrap Cost at 43% seal-fail reject fraction: a worked example in sterilization & sterile barrier manufacturing

Here is what the math looks like when conditions slip. We hold every other input steady and drop seal-fail reject fraction to 43%, then walk the calculation through step by step. Estimate the cost of scrapped sterile barrier packaging from seal failures and barrier defects across a production lot.

The inputs for this scenario

  • Pouches scrapped: 1,200 pouches (held at the documented default)
  • Loaded pouch material cost: 3.85 $/pouch (held at the documented default)
  • Seal-fail reject fraction: 43 % (the input this scenario stresses; the baseline uses 60)
  • Lot re-qualification fee: 450 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total scrap cost = pouches scrapped x loaded pouch cost x seal-fail % + re-qualification fee.
  • Total packaging scrap cost works out to 2,437 $ at these inputs, and this is the headline figure for the scenario.
  • Packaging scrap cost per unit works out to 2.03 $ / piece at these inputs.
  • Variable packaging scrap cost works out to 1,987 $ at these inputs.
  • Fixed packaging scrap cost adder works out to 450 $ at these inputs.

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 24.38% below the baseline at 2,437 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to seal-fail reject fraction, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The seal-fail fraction scales only the material cost; it assumes re-qualification is a single fixed fee and doesn't capture downstream costs like lost production time, expedited retest, or customer impact.

Results at a glance

  • Total packaging scrap cost: 2,437 $ (headline result)
  • Packaging scrap cost per unit: 2.03 $ / piece
  • Variable packaging scrap cost: 1,987 $
  • Fixed packaging scrap cost adder: 450 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Scrap Cost calculator, set seal-fail reject fraction to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.