Flavors, Fragrances & Aroma Chemicals worked example

Capacity Gap at 59% production availability: a worked example in flavors, fragrances & aroma chemicals

Suppose production availability falls to 59%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate usable production capacity for flavor, fragrance, extract, solvent blend, or aroma chemical operations so it can be compared with demand.

The inputs for this scenario

  • Accepted output per batch cycle: 450 kg / cycle (held at the documented default)
  • Available batch cycles: 18 cycles (held at the documented default)
  • Production availability: 59 % (the input this scenario stresses; the baseline uses 82)
  • First-pass release yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity gap = accepted output per batch cycle × available batch cycles.
  • Good capacity gap works out to 4,588 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity gap works out to 8,100 units at these inputs.
  • Capacity Gap downtime loss works out to 3,321 units at these inputs.
  • Capacity Gap yield loss works out to 191 units at these inputs.

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 28.05% below the baseline at 4,588 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Good capacity gap: 4,588 units (headline result)
  • Gross capacity gap: 8,100 units
  • Capacity Gap downtime loss: 3,321 units
  • Capacity Gap yield loss: 191 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Capacity Gap calculator, set production availability to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.