Mixing, Blending & Industrial Batch Processing worked example

CIP Cost at 61% recovery capture factor: a worked example

Suppose recovery capture factor falls to 61%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Cost a clean-in-place changeover from cycles per changeover, utility and chemical cost per cycle, recovery capture, and fixed lost production cost.

The inputs for this scenario

  • CIP cycles per changeover: 5 cycles (held at the documented default)
  • Utility and chemical cost per cycle: 38 $ / cycle (held at the documented default)
  • Recovery capture factor: 61 % (the input this scenario stresses; the baseline uses 85)
  • Lost production fixed cost: 180 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: CIP cost per changeover = cycles per changeover × utility and chemical cost per cycle × recovery capture factor + lost production fixed cost.
  • Weighted cost works out to 296 $ / changeover at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 59.18 $ / piece at these inputs.
  • Captured value works out to 116 $ at these inputs.
  • Fixed adjustment works out to 180 $ at these inputs.

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 13.35% below the baseline at 296 $ / 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Weighted cost: 296 $ / changeover (headline result)
  • Per piece value: 59.18 $ / piece
  • Captured value: 116 $
  • Fixed adjustment: 180 $

Run it with your numbers

  • To rerun this with your own numbers, open the live CIP Cost calculator, set recovery capture factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.