Interactive planning tool · user-entered factors only
From Rated BPH to Estimated Saleable Output
Rated bottles per hour is one input, not the factory result. This calculator applies your scheduled hours, planned stops, availability estimate, running-efficiency estimate and quality-yield estimate to show theoretical, produced and saleable bottles plus liters and the nameplate-to-saleable difference.
Illustrative arithmetic · replace every assumption
Worked Example: From 6,000 BPH to 28,728 Saleable Bottles
This example explains the calculator, not the expected performance of an Allot Tech machine or any installed factory. Assume one eight-hour shift, sixty minutes of planned stops, 80% availability, 90% running efficiency and a 95% saleable-quality yield. These chosen percentages are not recommended defaults.
Working formula6,000 bottles/hour × (8 − 60/60) hours × 0.80 × 0.90 × 0.95 = 28,728 estimated saleable bottles per shift
| Step | Calculation | Interpretation |
|---|---|---|
| Scheduled nameplate quantity | 6,000 × 8 = 48,000 bottles | A comparison quantity before planned stops or operating losses |
| Net planned production time | 8 − 60/60 = 7 hours | Subtract the sixty planned-stop minutes once |
| Available running time | 7 × 0.80 = 5.6 hours | Availability applies to the remaining seven hours, not the original shift again |
| Estimated produced bottles | 6,000 × 5.6 × 0.90 = 30,240 | Running efficiency represents rate loss during available time |
| Estimated saleable bottles | 30,240 × 0.95 = 28,728 | The quality factor represents the share expected to meet the defined saleable basis |
| Estimated saleable volume | 28,728 × 0.5 L = 14,364 L | Volume for the illustrative 500 mL format only |
Avoid double-counting: do not subtract planned stops twice, and do not include the same microstop in both downtime and running-speed loss. Use a consistent site counting rule. A forecast does not release real product; actual quality disposition controls what can be dispatched.
Actual records · reconcile one batch and cutoff time
Produced Bottles Are Not Automatically Released Bottles
Keep forecast quantities separate from actual counts. In a different illustrative batch, 30,000 filled bottles can reconcile as shown below. If stock moves from hold into released status later, update its disposition without counting that stock as new production.
| Status at the chosen cutoff | Bottles | Record needed |
|---|---|---|
| Rejected | 500 | Rejection and disposition record |
| Held pending decision | 1,000 | Hold location, reason and decision owner |
| Released | 28,500 | Authorized release record linked to the batch |
| Reconciled produced total | 500 + 1,000 + 28,500 = 30,000 | Matching batch, format, counting boundary and cutoff time |
Rework, retained samples, damaged stock or other statuses may require additional mutually exclusive categories in your factory. Investigate any unexplained count difference instead of forcing it into the released quantity.
Scenario discipline · define every factor
Interpret Saleable Output Without Hiding the Losses
Run separate scenarios when factors come from different evidence. A result is decision-ready only when the period, format, factor source and constrained process are visible.
| Input or result | What it means here | Evidence source | Do not confuse it with |
|---|---|---|---|
| Rated filler speed | The entered machine rate under its stated basis | Confirmed proposal or test record | Guaranteed connected-line output |
| Availability | Entered share of net scheduled time when equipment can run | Downtime-coded production record | Running efficiency while available |
| Running efficiency | Entered performance while the line is available | Counts and run-time evidence | Quality yield or released product |
| Quality yield | Entered share of produced bottles treated as saleable | Reject, hold and release records | All produced bottles |
| Nameplate-to-saleable gap | Scenario difference requiring loss-tree review | Calculator result plus factory records | A diagnosed root cause |
Saleable output calculator
Enter your own operating factors
No efficiency factor is prefilled. Use values supported by your plan or factory records.
Preliminary output scenario
Complete all fields to compare theoretical, produced and saleable output.
This calculator provides a preliminary operating scenario. Actual output depends on confirmed machine conditions, bottle formats, materials, utilities, operators, maintenance and acceptance criteria.
01 · Buyer or factory inputs
Information the decision needs
- Rated filler speed in bottles per hour
- Scheduled hours per shift and planned stop minutes
- User-estimated availability
- User-estimated running efficiency
- User-estimated quality yield
- Bottle volume in liters
- Shifts per day and working days per month
02 · Operating objective
What completion should achieve
Make operating assumptions explicit and provide a reproducible preliminary scenario without inserting invented industry benchmarks.
03 · Required controls
Turn the objective into controlled work
- 01
Use one clearly defined bottle format and filler rating basis
- 02
Enter only factors supported by your plan or actual records
- 03
Keep percentages between zero and one hundred
- 04
Record planned stops separately from unplanned availability loss
- 05
Review whether upstream and downstream machines can sustain the entered basis
- 06
Recalculate when materials, bottle format, shift or equipment conditions change
04 · Factory interfaces
What connects to this decision
- Scheduled time to staffing and production plan
- Availability to downtime and maintenance control
- Running efficiency to speed loss and line balance
- Quality yield to rejects, holds and product release
- Saleable output to warehouse and dispatch capacity
05 · Evidence to collect
Records that make review possible
- Machine rating and bottle basis
- Approved shift schedule
- Downtime log
- Speed-loss or production-count record
- Reject and quality-hold data
- Finished-product release quantity
06 · Common failure modes
Do not confuse a pattern with a confirmed cause
1Using a catalog maximum without confirming the project basis
2Entering borrowed efficiency assumptions as fact
3Counting held or rejected bottles as saleable
4Ignoring planned cleaning or changeover stops
5Treating the result as a contractual performance guarantee
07 · Responsibility boundary
Name who confirms each part
| Role | Possible responsibility in this stage |
|---|---|
| Factory team | Provide the operating schedule and evidence-based factors. |
| Equipment supplier | Confirm the machine rating basis and agreed acceptance conditions. |
| Quality team | Confirm what counts as released saleable product. |
| Allot Tech | Use submitted assumptions only as a preliminary discussion basis. |
08 · Completion criteria
Evidence that the stage can advance
- All required inputs pass validation
- The result separates theoretical, produced and saleable quantities
- The difference from nameplate output is visible
- The assumptions and disclaimer stay attached to the copied result
- The result can be carried into the factory review form
Contact and support
Questions operating teams ask
Does the calculator use an industry-standard efficiency?
No. Availability, running efficiency and quality yield are entered by the user. The tool does not invent a standard.
Why are planned stops separate from availability?
Planned stops reduce the scheduled operating window before availability is applied. This keeps the assumptions visible and avoids silently mixing different loss definitions.
Is calculated output a guarantee?
No. It is a preliminary operating scenario. Actual output depends on confirmed equipment conditions, formats, materials, utilities, operators, maintenance and acceptance criteria.
Editorial responsibility: Allot Tech (Suzhou) Co., Ltd. · Last updated .