ClearpackIQ
Packaging Intelligence. Built In.
LIVE — Current Shift
Executive KPI Summary — Current Shift vs. Best-Run Benchmark
Cost per Bottle
$0.2741
▲ +8.3% vs $0.253 target
OEE
68.4%
▼ −6.6 pts vs 75% target
Energy / 1,000 btl
305 kWh
▲ 3,100 kWh ÷ 10,180 bottles
Yield — RM → Packed
98.1%
▼ −0.9 pts vs 99% target
Batch Summary
Line 2 · Batch #B-2024-1047 · Shift A
Packed Bottles
10,180
Batch Cost
$2,791
RM Input
5,190 kg
Shift Duration
600 min
Total kWh
3,100
Fully-Loaded $/btl
$0.2741
Process Cost
$1,746
Packaging Cost
$1,045
Cost per Bottle — Build-Up
$2,790.60 total batch cost ÷ 10,180 packed bottles = $0.2741/bottle
Energy Waste — Shift Profile
3,100 kWh total · 24% non-productive · $65.50 wasteful cost
Section 1 — Process Side · Bulk Preparation, Mixing, Holding + CIP
Process Cost & Utilities
Benchmarked against best-run passport. CIP rows prorated to 5,090 L basis.
$1,746.00 total
Utility Unit Actual Benchmark Variance Cost ($)
Electricity kWh 1,840 1,680 +9.5% 184.00
Steam kg 2,250 2,138 +5.2% 112.50
Chilled Water m³ 48 45.8 +4.8% 38.40
Compressed Air Nm³ 620 590 +5.1% 31.00
Process RM kg 5,190 5,090 +2.0% 1,245.60
CIP Caustic kg 45 40 +12.5% 54.00
CIP Acid kg 25 22 +13.6% 37.50
CIP Water m³ 8 7 +14.3% 16.00
CIP Steam kg 350 300 +16.7% 17.50
CIP Electricity kWh 95 80 +18.8% 9.50
Total Process Cost $1,746.00
Process — % Variance from Benchmark
All 10 items above benchmark · CIP Elec. +18.8% highest · ■ Utilities  ■ Process RM  ■ CIP
Section 2 — Packaging Side · Filling, Capping, Labelling
Packaging Cost & Materials
RM-to-packed-bottle yield drives unit cost denominator
$1,044.60 total
Line Item Unit Actual Benchmark Variance Cost ($)
Electricity kWh 1,260 1,222 +3.1% 126.00
Compressed Air Nm³ 980 916 +7.0% 49.00
Bottles pcs 10,420 10,200 +2.2% 521.00
Caps pcs 10,380 10,200 +1.8% 103.80
Labels pcs 10,520 10,200 +3.1% 157.80
Cases pcs 870 850 +2.4% 87.00
Total Packaging Cost $1,044.60
Packaging Materials — Variance % vs. Benchmark
Compressed air +7.0% · Electricity +3.1% · Labels +3.1% — top overspend drivers
Section 3 — Yield · Raw Material to Packed Bottle
Component Yield Analysis
Per-component loss tagged at source. Target: 99% across all components.
RM Liquid
98.1%
Bottles
97.7%
Caps
98.1%
Labels
96.8%
Cases
97.5%
Component Input Output Loss Primary Driver
RM Liquid (L) 5,190 5,090 100 Tank heel — last ~100 L not pumpable; line/filler residue
Bottles (pcs) 10,420 10,180 240 Filler reject, conveyor breakage
Caps (pcs) 10,380 10,180 200 Capper jam, misalign
Labels (pcs) 10,520 10,180 340 Reject, wrinkle, misprint
Cases (pcs) 870 848 22 Case erector jam
Packed FG — 10,180 — —
Energy Waste Tracker — Useful vs. Wasteful
3,100 kWh shift total · 655 kWh wasteful (21.1%) · 90 kWh necessary losses
Wasteful kWh
655
21.1% of shift
Direct Cost
$65.50
this shift
Recoverable / yr
$71,800
3 shifts × 365 days
655 kWh wasteful per shift · $65.50 direct cost · Annualised (3 shifts × 365 days): ~$71,800 / year in recoverable energy waste
Live Issues
Process Electricity +9.5% over benchmark — $16 impact this batch
Label yield 96.8% — 340 units lost · $157.80 cost impact
CIP chemicals 12–19% over benchmark — $21.50 overspend/batch
Pkg. compressed air +7.0% since 06:40 — $3.20 direct impact
ClearpackIQ AI
Ask about this batch — costs, yield, energy, actions
Hi! Ask me anything — costs, yield, energy waste, or what to fix first.
Biggest overrun Label yield Energy cost Fix first Process charts