What this calculator does
This calculator converts average overfill above target into annual product quantity and cost. Use measured results from a representative production period and keep underfill compliance separate. The aim is to centre a capable process, not to target below the declared quantity.
Enter your figures and select calculate.
Planning estimate: Annual giveaway kg = average overfill grams × units per day × production days ÷ 1,000. Annual cost = giveaway kg × product cost per kg.
Measure the true average overfill
Use individual net-fill results across normal product, pack, temperature and supply conditions. Do not estimate from one visual fill level.
- Subtract accurate container tare
- Use an appropriate sample size
- Include start-up and end-of-run conditions
Keep compliance and optimisation separate
The declared quantity and applicable quantity-control system must be respected. Process improvement reduces variation and centres the process safely.
- Define target and legal control limits
- Investigate drift and outliers
- Calibrate the measurement system
Prioritise the causes of variation
Product temperature, density, air, supply pressure, nozzle shut-off, wear and container handling can all shift results.
- Change one controlled condition at a time
- Trend average and range
- Verify benefit after maintenance or adjustment