Industrial Gases & Cryogenic Systems worked example

Fill Plant Capacity at 63% expected fill plant uptime: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected fill plant uptime to 63%, then walk the calculation through step by step. Estimate accepted fill plant capacity from cylinders per fill cycle, available cycles, plant uptime, and first-pass release yield.

The inputs for this scenario

  • Cylinders or containers per fill cycle: 24 cylinders / cycle (held at the documented default)
  • Available fill cycles: 18 cycles (held at the documented default)
  • Expected fill plant uptime: 63 % (the input this scenario stresses; the baseline uses 88)
  • First-pass release yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross fill plant capacity = cylinders or containers per fill cycle × available fill cycles.
  • Good fill plant capacity works out to 261 cylinders at these inputs, and this is the headline figure for the scenario.
  • Gross fill plant capacity works out to 432 cylinders at these inputs.
  • Fill plant downtime loss works out to 160 cylinders at these inputs.
  • First-pass release yield loss works out to 10.89 cylinders at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where expected fill plant uptime sits at 88% and the headline result is 365 cylinders, this scenario comes in 28.41% below the baseline at 261 cylinders.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected fill plant uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a fixed cylinders-per-cycle rack size; mixed cylinder sizes, gas changeovers, and purge-down losses between products aren't modeled and would reduce real output further.

Results at a glance

  • Good fill plant capacity: 261 cylinders (headline result)
  • Gross fill plant capacity: 432 cylinders
  • Fill plant downtime loss: 160 cylinders
  • First-pass release yield loss: 10.89 cylinders

Run it with your numbers

  • To rerun this with your own numbers, open the live Fill Plant Capacity calculator, set expected fill plant uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.