Heat Exchanger, Coil & Radiator Manufacturing worked example

Airflow Capacity at 99% airflow bench uptime: a worked example

What does the result look like when airflow bench uptime reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when an airflow bench, wind tunnel, fan test stand, or final performance station limits the number of thermal products that can be released.

The inputs for this scenario

  • Coils tested per airflow cycle: 4 coils / cycle (unchanged)
  • Usable airflow test cycles: 30 cycles / shift (unchanged)
  • Airflow bench uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass airflow yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross airflow test capacity = coils tested per cycle × usable airflow test cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 115 coils / shift for good airflow-tested output, the number this scenario is built around.
  • At this operating point the engine returns 120 coils / shift for gross airflow test capacity.
  • At this operating point the engine returns 1.2 coils / shift for airflow bench downtime loss.
  • At this operating point the engine returns 3.56 coils / shift for airflow reject loss.

How this compares with the baseline

  • Against the tool's baseline example, where airflow bench uptime sits at 90% and the headline result is 105 coils / shift, this scenario comes in 10% above the baseline at 115 coils / shift.
  • A figure at this level is achievable when airflow bench uptime is genuinely sustained, not just peaked for a shift. It assumes uptime and yield are independent and steady across the shift; a clustered bench failure or a bad fin-stock lot can swing real output well below the calculated figure.

Results at a glance

  • Good airflow-tested output: 115 coils / shift (headline result)
  • Gross airflow test capacity: 120 coils / shift
  • Airflow bench downtime loss: 1.2 coils / shift
  • Airflow reject loss: 3.56 coils / shift

Run it with your numbers

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

Last reviewed 2026-05-12.