Food & Beverage Manufacturing worked example

Batch Loss with starting batch input weight of 500 lb: a worked example

This worked example runs the batch loss numbers for a tougher week than the baseline: starting batch input weight of 500 lb instead of the typical 1,000 lb. Estimate remaining usable batch quantity after known losses such as cook loss, transfer loss, purge, samples, rejects, and hold-up.

The inputs for this scenario

  • Starting batch input weight: 500 lb (the input this scenario stresses; the baseline uses 1,000)
  • Cook, moisture, or shrink loss: 38 lb (held at the documented default)
  • Transfer, line hold-up, or purge loss: 22 lb (held at the documented default)
  • Samples, rejects, or rework hold: 10 lb (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total batch loss deductions = cook, moisture, or shrink loss + transfer, line hold-up, or purge loss + samples, rejects, or rework hold.
  • Remaining batch loss works out to 430 units at these inputs, and this is the headline figure for the scenario.
  • Total batch loss deductions works out to 70 value at these inputs.
  • Starting batch input works out to 500 value at these inputs.
  • Utilization works out to 86 % at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where starting batch input weight sits at 1,000 lb and the headline result is 930 units, this scenario comes in 53.76% below the baseline at 430 units.
  • Use it during yield investigations, daily batch reconciliation, or when comparing line performance against a target utilization. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Remaining batch loss: 430 units (headline result)
  • Total batch loss deductions: 70 value
  • Starting batch input: 500 value
  • Utilization: 86 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Batch Loss calculator, set starting batch input weight to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.