Mixing, Blending & Industrial Batch Processing worked example

Powder Wet-Out Time at 23% dispersion allowance: a worked example

What does the result look like when dispersion allowance reaches 23%? The full calculation is worked below with real intermediate numbers. Use it when a high-shear blend with sticky or fluffy powders is being scheduled and you need realistic wet-out hours before the batch can move on.

The inputs for this scenario

  • Powder charge: 80 kg (unchanged)
  • Mixer wet-out rate: 240 kg / hr (unchanged)
  • Dispersion allowance: 23 % (raised for this scenario; the documented default is 20)

Working through the calculation

  • Applying the documented formula (Base wet-out time = powder charge รท mixer wet-out rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 0.41 hr for adjusted run time, the number this scenario is built around.
  • At this operating point the engine returns 0.33 hr for base run time.
  • At this operating point the engine returns 23 % for allowance applied.
  • At this operating point the engine returns 240 pieces / min for process rate.

How this compares with the baseline

  • Against the tool's baseline example, where dispersion allowance sits at 20% and the headline result is 0.4 hr, this scenario comes in 2.5% above the baseline at 0.41 hr.
  • A figure at this level is achievable when dispersion allowance is genuinely sustained, not just peaked for a shift. It models wet-out as a constant rate, so it won't capture powders that wet slowly at first then accelerate, or rate changes from temperature, surfactant, or impeller speed.

Results at a glance

  • Adjusted run time: 0.41 hr (headline result)
  • Base run time: 0.33 hr
  • Allowance applied: 23 %
  • Process rate: 240 pieces / min

Run it with your numbers

  • Every input above is editable in the live Powder Wet-Out Time calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.