Mixing, Blending & Industrial Batch Processing worked example

Batch Cost at 68% material capture factor: a worked example

Suppose material capture factor falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Build a defensible batch cost from material weight, blended material rate, capture factor, and fixed overhead per batch.

The inputs for this scenario

  • Batch material weight: 250 kg (held at the documented default)
  • Blended material rate: 4.5 $ / kg (held at the documented default)
  • Material capture factor: 68 % (the input this scenario stresses; the baseline uses 95)
  • Fixed overhead per batch: 180 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Batch cost = batch material weight × blended material rate × capture factor + fixed overhead.
  • Weighted cost works out to 945 $ / batch at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 3.78 $ / piece at these inputs.
  • Captured value works out to 765 $ at these inputs.
  • Fixed adjustment works out to 180 $ at these inputs.

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 24.32% below the baseline at 945 $ / 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Weighted cost: 945 $ / batch (headline result)
  • Per piece value: 3.78 $ / piece
  • Captured value: 765 $
  • Fixed adjustment: 180 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Batch Cost calculator, set material capture factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.