Sterilization & Sterile Barrier Manufacturing worked example

Sterile Barrier Seal Strength at 12% aql sampling share: a worked example

Push aql sampling share up to 12% and the picture changes. This example computes every intermediate figure at that operating point. A packaging engineer budgeting peel and burst testing for a sterile pouch seal under an ISO 11607 sampling plan.

The inputs for this scenario

  • Pouches Seal-Tested: 120 pouches (unchanged)
  • Cost per Seal Test: 18 $/pouch (unchanged)
  • AQL Sampling Share: 12 % (raised for this scenario; the documented default is 10)
  • Seal Validation Setup: 1,800 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total seal-strength cost = pouches tested x cost per seal test x AQL sampling share + seal validation setup) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,059 $ for total sterile barrier seal strength cost, the number this scenario is built around.
  • At this operating point the engine returns 17.16 $ / piece for sterile barrier seal strength cost per unit.
  • At this operating point the engine returns 259 $ for variable sterile barrier seal strength cost.
  • At this operating point the engine returns 1,800 $ for fixed sterile barrier seal strength adder.

How this compares with the baseline

  • Against the tool's baseline example, where aql sampling share sits at 10% and the headline result is 2,016 $, this scenario comes in 2.14% above the baseline at 2,059 $.
  • It computes total seal-strength testing cost as pouches tested times per-test cost scaled by the AQL sampling share, plus a fixed validation setup fee, then divides for cost per tested pouch. 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

  • Total sterile barrier seal strength cost: 2,059 $ (headline result)
  • Sterile barrier seal strength cost per unit: 17.16 $ / piece
  • Variable sterile barrier seal strength cost: 259 $
  • Fixed sterile barrier seal strength adder: 1,800 $

Run it with your numbers

  • Every input above is editable in the live Sterile Barrier Seal Strength calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.