Mixing, Blending & Industrial Batch Processing worked example

CIP Cost at 98% recovery capture factor: a worked example

Push recovery capture factor up to 98% and the picture changes. This example computes every intermediate figure at that operating point. Use it when planning a product changeover or quoting a campaign and you need a defensible CIP cost per changeover that includes lost batch time.

The inputs for this scenario

  • CIP cycles per changeover: 5 cycles (unchanged)
  • Utility and chemical cost per cycle: 38 $ / cycle (unchanged)
  • Recovery capture factor: 98 % (raised for this scenario; the documented default is 85)
  • Lost production fixed cost: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (CIP cost per changeover = cycles per changeover × utility and chemical cost per cycle × recovery capture factor + lost production fixed cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 366 $ / changeover for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 73.24 $ / piece for per piece value.
  • At this operating point the engine returns 186 $ for captured value.
  • At this operating point the engine returns 180 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where recovery capture factor sits at 85% and the headline result is 342 $ / changeover, this scenario comes in 7.23% above the baseline at 366 $ / changeover.
  • It computes total CIP cost per changeover as cycles times per-cycle utility and chemical cost adjusted by a recovery capture factor, plus a fixed lost-production cost, and returns cost per cycle. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Weighted cost: 366 $ / changeover (headline result)
  • Per piece value: 73.24 $ / piece
  • Captured value: 186 $
  • Fixed adjustment: 180 $

Run it with your numbers

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

Last reviewed 2026-05-12.