Compare theoretical vs. actual number of packs obtained, with QC/retention sample packs shown as part of the loss breakdown.
Packing reconciliation is the final material-balance check in solid dosage manufacturing, comparing the theoretical number of packs the batch should yield against the finished, accepted packs actually obtained.
Enter the theoretical number of packs from your batch formula, the actual number of packs obtained, and the number of packs pulled for QC, stability, or retention samples. The calculator works out the total pack-count loss, then breaks that loss down into the sample packs you entered and any remaining, unexplained loss — so both are visible together instead of one masking the other.
Since this is typically the last reconciliation step before a batch is released, showing sample packs as part of the loss breakdown — rather than hiding them — keeps the batch record fully auditable: a reviewer can see at a glance how much of the shortfall was a planned sample pull, and how much still needs investigating.
Packing reconciliation closes out the batch record's material balance, and because it's the final step, any loss here is effectively the last chance to catch a discrepancy before release. Packs are commonly reduced by missing or damaged leaflets, carton print defects, incomplete blister counts, or QC/stability/retention sampling. Showing sample packs as their own line inside the total loss — rather than deducting them beforehand — gives QA a transparent, auditable breakdown of exactly where every pack went.
Theoretical number of packs is entered directly from your batch manufacturing formula — typically total blisters produced divided by blisters per pack, calculated upstream of this step.
Showing sample packs as their own line within the total loss keeps the full pack-count reconciliation visible in one place, so a reviewer can see both the planned sample deduction and any remaining unexplained loss side by side.
Common causes include packs rejected for missing or damaged leaflets, carton print or seal defects, and incomplete or short blister counts caught during in-process checks.