Mixing, Blending & Industrial Batch Processing worked example

Batch Size at 65% effective mixer uptime: a worked example in mixing, blending & industrial batch processing

Here is what the math looks like when conditions slip. We hold every other input steady and drop effective mixer uptime to 65%, then walk the calculation through step by step. Size good batches per shift from output per batch, scheduled batches, mixer uptime, and first-pass yield.

The inputs for this scenario

  • Output per batch: 4 units / batch (held at the documented default)
  • Batches scheduled per shift: 480 batches (held at the documented default)
  • Effective mixer uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass batch yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross batch output = output per batch × batches scheduled per shift.
  • Good output capacity works out to 1,211 batches at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 1,920 batches at these inputs.
  • Uptime loss works out to 672 batches at these inputs.
  • Yield loss works out to 37.44 batches at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where effective mixer uptime sits at 90% and the headline result is 1,676 batches, this scenario comes in 27.78% below the baseline at 1,211 batches.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to effective mixer uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It treats uptime and yield as independent flat percentages; real lines see correlated losses (a fouled mixer both runs slower and yields worse), so validate the inputs against logged shift data.

Results at a glance

  • Good output capacity: 1,211 batches (headline result)
  • Gross capacity: 1,920 batches
  • Uptime loss: 672 batches
  • Yield loss: 37.44 batches

Run it with your numbers

  • To rerun this with your own numbers, open the live Batch Size calculator, set effective mixer uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.