Weighing, Dosing & Loss-in-Weight Feeding worked example

Overfeed Cost at 58% recoverable and captured fraction: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop recoverable and captured fraction to 58%, then walk the calculation through step by step. Overfeed cost quantifies the money lost when a dosing or loss-in-weight feeder consistently delivers more material than the recipe calls for.

The inputs for this scenario

  • Overfed quantity over the run: 100 units (held at the documented default)
  • Material cost per overfed unit: 45 $ / unit (held at the documented default)
  • Recoverable / captured fraction: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed rework or adjustment cost: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Overfeed Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where recoverable and captured fraction sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to recoverable and captured fraction, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It prices the raw material giveaway and a fixed adjustment charge only; it does not value downstream quality effects, spec violations, or scrapped finished goods caused by overdosing.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Overfeed Cost calculator, set recoverable and captured fraction to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.