Flavors, Fragrances & Aroma Chemicals worked example

Capacity Gap at 94% production availability: a worked example in flavors, fragrances & aroma chemicals

Push production availability up to 94% and the picture changes. This example computes every intermediate figure at that operating point. Use it when deciding whether compounding kettles, reactors, filters, QC, packaging, or cleaning windows can cover the forecast.

The inputs for this scenario

  • Accepted output per batch cycle: 450 kg / cycle (unchanged)
  • Available batch cycles: 18 cycles (unchanged)
  • Production availability: 94 % (raised for this scenario; the documented default is 82)
  • First-pass release yield: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross capacity gap = accepted output per batch cycle × available batch cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 7,309 units for good capacity gap, the number this scenario is built around.
  • At this operating point the engine returns 8,100 units for gross capacity gap.
  • At this operating point the engine returns 486 units for capacity gap downtime loss.
  • At this operating point the engine returns 305 units for capacity gap yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where production availability sits at 82% and the headline result is 6,376 units, this scenario comes in 14.63% above the baseline at 7,309 units.
  • It computes good (saleable) capacity as accepted output per cycle times available cycles, then derates that gross figure by production availability and first-pass release yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good capacity gap: 7,309 units (headline result)
  • Gross capacity gap: 8,100 units
  • Capacity Gap downtime loss: 486 units
  • Capacity Gap yield loss: 305 units

Run it with your numbers

  • Every input above is editable in the live Capacity Gap calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.