Reconcile fill material against filled capsules obtained, on a capsule-count basis.
Encapsulation reconciliation compares the fill material — powder, granules, or pellets — charged into the capsule filling machine against the filled capsules actually obtained, converting both sides into capsule counts.
Because a filled capsule's weight includes both the fill material and the empty shell, this calculator derives the theoretical filled capsule weight by adding the shell weight to the target fill weight, giving an expected total filled-batch weight that accounts for the shell rather than treating the fill material and finished capsules as directly comparable by weight.
The actual side uses a separately measured average filled capsule weight, so any drift between the target fill weight and what capsules are actually filling to becomes visible alongside the reconciliation itself.
Encapsulation loss tends to concentrate around a few specific causes — capsules rejected for being underweight, overweight, or visibly defective during in-process checks, and fill material lost to dust collection or machine surfaces during the filling run. Separating target fill weight from shell weight, and empirical average filled weight from theoretical filled weight, gives a more defensible reconciliation than a single lumped weight comparison.
Add the target fill weight (powder, granules, or pellets) to the average empty capsule shell weight.
Common causes include capsules rejected during in-process weight checks, fill material lost to dust collection, and mechanical rejects from the filling machine.