Mixing, Blending & Industrial Batch Processing worked example

Batch Cost at 99% material capture factor: a worked example

Push material capture factor up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when a recipe is being put through a weighted-cost review and finance needs a per-batch material and overhead number, not just standard cost.

The inputs for this scenario

  • Batch material weight: 250 kg (unchanged)
  • Blended material rate: 4.5 $ / kg (unchanged)
  • Material capture factor: 99 % (raised for this scenario; the documented default is 95)
  • Fixed overhead per batch: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Batch cost = batch material weight × blended material rate × capture factor + fixed overhead) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,294 $ / batch for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 5.18 $ / piece for per piece value.
  • At this operating point the engine returns 1,114 $ for captured value.
  • At this operating point the engine returns 180 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where material capture factor sits at 95% and the headline result is 1,249 $ / batch, this scenario comes in 3.6% above the baseline at 1,294 $ / batch.
  • It computes total batch cost from material weight times blended rate times capture factor plus fixed overhead, then divides by weight to give cost per kg. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Weighted cost: 1,294 $ / batch (headline result)
  • Per piece value: 5.18 $ / piece
  • Captured value: 1,114 $
  • Fixed adjustment: 180 $

Run it with your numbers

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

Last reviewed 2026-05-12.