Grain Milling, Dry Bulk Food & Feed Handling worked example

Rework/Feed Return at 59% rework handling efficiency: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop rework handling efficiency to 59%, then walk the calculation through step by step. Estimate the practical rate for rework or feed return processing by comparing returned product weight with runtime and rework handling efficiency.

The inputs for this scenario

  • Returned or rework weight to re-handle: 12,000 lb (held at the documented default)
  • Rework handling runtime: 6 hr (held at the documented default)
  • Rework handling efficiency: 59 % (the input this scenario stresses; the baseline uses 82)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw rework/feed return throughput = returned or rework weight รท rework handling runtime.
  • Effective throughput works out to 1,180 lb / hr at these inputs, and this is the headline figure for the scenario.
  • Raw rework/feed return throughput works out to 2,000 lb / hr at these inputs.
  • Efficiency works out to 59 % at these inputs.
  • Runtime works out to 6 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where rework handling efficiency sits at 82% and the headline result is 1,640 lb / hr, this scenario comes in 28.05% below the baseline at 1,180 lb / hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to rework handling efficiency, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes the efficiency factor captures all losses; surge-bin bottlenecks, blend-ratio limits that cap how much rework a clean lot can absorb, and quality holds are not modeled.

Results at a glance

  • Effective throughput: 1,180 lb / hr (headline result)
  • Raw rework/feed return throughput: 2,000 lb / hr
  • Efficiency: 59 %
  • Runtime: 6 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Rework/Feed Return calculator, set rework handling efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.