Mixing, Blending & Industrial Batch Processing calculator
Batch Size Calculator
Find the charged mass each complete batch needs to meet your shift demand. Enter the time budget, demonstrated cycle and mass yield, plus your approved batch limit.
What this calculator does
- Size each complete batch to meet good-mass demand within your shift and approved mixer limit.
Formula used
- Complete batches = floor((shift hours − downtime hours) × 60 ÷ cycle minutes)
- Required charge = good demand ÷ (complete batches × mass yield ÷ 100)
- Effective uptime = (shift hours − downtime hours) ÷ shift hours × 100
- Good mass per batch = good demand ÷ complete batches
- Charge over limit = max(0, required charge − approved maximum)
Inputs explained
- Required Good Mass: Released product required by the shift production order.
- Scheduled Shift Length: Elapsed shift length from the production schedule.
- Downtime Outside Batch Cycles: Shift stops not already included in complete cycle time.
- Complete Batch Cycle: Measured charging, mixing, discharge, and between-batch cleaning time.
- Observed Good-Mass Yield: Good recovered mass divided by charged mass from comparable runs.
- Approved Maximum Batch Mass: Product-specific charge limit from approved operating records.
How to use the result
- Best suited to shift charge planning, downtime recovery planning.
- This demand calculation does not establish mixing quality, minimum fill, or a new equipment rating.
Common questions
- Why does batch size jump when downtime changes? Only complete batches count. Losing enough time to remove one complete cycle increases the charge required from each remaining batch.
- Does a smaller batch always use the same cycle? No. Use a cycle demonstrated at the proposed charge. Charging, heating, dispersion, discharge, and cleaning can respond differently to batch size.
- Which yield belongs in this calculation? Use good recovered mass divided by charged mass for comparable batches. A percentage of batches passing inspection is a different measurement.
- Can I use a result above the mixer limit? No. It identifies an infeasible plan against your entered limit. Increase available time, change the demonstrated cycle, or allocate another suitable mixer.
Last reviewed 2026-10-01.