Grain Milling, Dry Bulk Food & Feed Handling worked example

Batch Blend Accuracy with actual ingredient weight added to batch of 2,500 lb: a worked example

What does the result look like when actual ingredient weight added to batch reaches 2,500 lb? The full calculation is worked below with real intermediate numbers. Use it when a feed mill, premix room, flour blending system, or dry ingredient process needs to verify whether formula additions are inside tolerance before release.

The inputs for this scenario

  • Actual ingredient weight added to batch: 2,500 lb (raised for this scenario; the documented default is 1,005)
  • Formula target ingredient weight: 1,000 lb (unchanged)
  • Batch tolerance reference weight: 1,000 lb (unchanged)

Working through the calculation

  • Applying the documented formula (Blend accuracy margin = actual ingredient addition - required formula addition) to the inputs above produces each figure below.
  • At this operating point the engine returns 150 % for blend accuracy weight margin, the number this scenario is built around.
  • At this operating point the engine returns 1,500 value for absolute margin.
  • At this operating point the engine returns 2,500 value for available amount.
  • At this operating point the engine returns 1,000 value for required amount.

How this compares with the baseline

  • Against the tool's baseline example, where actual ingredient weight added to batch sits at 1,005 lb and the headline result is 0.5 %, this scenario comes in 29,900% above the baseline at 150 %.
  • A figure at this level is achievable when actual ingredient weight added to batch is genuinely sustained, not just peaked for a shift. It checks a single ingredient against its target; it does not catch sequencing errors, wrong-ingredient substitutions, or mixer non-uniformity.

Results at a glance

  • Blend accuracy weight margin: 150 % (headline result)
  • Absolute margin: 1,500 value
  • Available amount: 2,500 value
  • Required amount: 1,000 value

Run it with your numbers

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

Last reviewed 2026-05-12.