Mixing, Blending & Industrial Batch Processing worked example

Capacity Gap with available batches per week of 110 batches: a worked example in mixing, blending & industrial batch processing

What does the result look like when available batches per week reaches 110 batches? The full calculation is worked below with real intermediate numbers. Use it during S&OP or weekly production planning when sales asks if the batch plant can absorb a new campaign without adding shifts.

The inputs for this scenario

  • Available batches per week: 110 batches (raised for this scenario; the documented default is 42)
  • Required batches per week: 38 batches (unchanged)
  • Planned capacity baseline: 40 batches (unchanged)

Working through the calculation

  • Applying the documented formula (Capacity headroom = available batches per week - required batches per week) to the inputs above produces each figure below.
  • At this operating point the engine returns 180 % for margin, the number this scenario is built around.
  • At this operating point the engine returns 72 value for absolute margin.
  • At this operating point the engine returns 110 value for available amount.
  • At this operating point the engine returns 38 value for required amount.

How this compares with the baseline

  • Against the tool's baseline example, where available batches per week sits at 42 batches and the headline result is 10 %, this scenario comes in 1,700% above the baseline at 180 %.
  • A figure at this level is achievable when available batches per week is genuinely sustained, not just peaked for a shift. It assumes all batches are interchangeable in size and run time; a mix of large and small or fast and slow recipes can make the simple batch count misleading.

Results at a glance

  • Margin: 180 % (headline result)
  • Absolute margin: 72 value
  • Available amount: 110 value
  • Required amount: 38 value

Run it with your numbers

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

Last reviewed 2026-05-12.