Heat Exchanger, Coil & Radiator Manufacturing worked example

Airflow Capacity at 65% airflow bench uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop airflow bench uptime to 65%, then walk the calculation through step by step. Estimate good airflow test capacity per shift for coils, radiators, condensers, evaporators, and fan-coil assemblies.

The inputs for this scenario

  • Coils tested per airflow cycle: 4 coils / cycle (held at the documented default)
  • Usable airflow test cycles: 30 cycles / shift (held at the documented default)
  • Airflow bench uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass airflow yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross airflow test capacity = coils tested per cycle × usable airflow test cycles.
  • Good airflow-tested output works out to 75.66 coils / shift at these inputs, and this is the headline figure for the scenario.
  • Gross airflow test capacity works out to 120 coils / shift at these inputs.
  • Airflow bench downtime loss works out to 42 coils / shift at these inputs.
  • Airflow reject loss works out to 2.34 coils / shift at these inputs.

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 27.78% below the baseline at 75.66 coils / shift.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to airflow bench uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 75.66 coils / shift (headline result)
  • Gross airflow test capacity: 120 coils / shift
  • Airflow bench downtime loss: 42 coils / shift
  • Airflow reject loss: 2.34 coils / shift

Run it with your numbers

  • To rerun this with your own numbers, open the live Airflow Capacity calculator, set airflow bench uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.