Mixing, Blending & Industrial Batch Processing worked example

Capacity Gap with available batches per week of 21 batches: a worked example in mixing, blending & industrial batch processing

This worked example runs the capacity gap numbers for a tougher week than the baseline: available batches per week of 21 batches instead of the typical 42 batches. Compare available batches per week against required batches per week and the planned baseline to see capacity headroom or shortfall.

The inputs for this scenario

  • Available batches per week: 21 batches (the input this scenario stresses; the baseline uses 42)
  • Required batches per week: 38 batches (held at the documented default)
  • Planned capacity baseline: 40 batches (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Capacity headroom = available batches per week - required batches per week.
  • Margin works out to -42.5 % at these inputs, and this is the headline figure for the scenario.
  • Absolute margin works out to -17 value at these inputs.
  • Available amount works out to 21 value at these inputs.
  • Required amount works out to 38 value at these inputs.

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 525% below the baseline at -42.5 %.
  • Use it in weekly or monthly planning to check whether a blending line can absorb the demand plan and still leave room for changeovers and downtime. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Margin: -42.5 % (headline result)
  • Absolute margin: -17 value
  • Available amount: 21 value
  • Required amount: 38 value

Run it with your numbers

  • To rerun this with your own numbers, open the live Capacity Gap calculator, set available batches per week to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.