Mixing, Blending & Industrial Batch Processing worked example

Scale-Up Ratio with pilot batch size of 50 L: a worked example

This scenario runs the scale-up ratio calculation on the strong side: pilot batch size of 50 L, with every other input held at its documented default. Use it when a formulation team is moving a recipe from pilot to plant and needs a production batch size that respects mixer geometry and process losses.

The inputs for this scenario

  • Pilot batch size: 50 L (raised for this scenario; the documented default is 20)
  • Scale-up factor: 100 x (unchanged)
  • Geometric correction: 0.95 x (unchanged)
  • Process efficiency multiplier: 0.97 x (unchanged)

Working through the calculation

  • Applying the documented formula (Production batch size = pilot batch size × scale-up factor × geometric correction × process efficiency multiplier) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,608 L / batch for result, the number this scenario is built around.
  • At this operating point the engine returns 4,750 value for base product.
  • At this operating point the engine returns 0.97 x for multiplier.
  • At this operating point the engine returns 5,000 value for factor a x b.

How this compares with the baseline

  • Against the tool's baseline example, where pilot batch size sits at 20 L and the headline result is 1,843 L / batch, this scenario comes in 150% above the baseline at 4,608 L / batch.
  • Use it during tech transfer or process development when projecting how much usable product a production batch will yield from a proven pilot. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Result: 4,608 L / batch (headline result)
  • Base product: 4,750 value
  • Multiplier: 0.97 x
  • Factor A x B: 5,000 value

Run it with your numbers

  • Every input above is editable in the live Scale-Up Ratio calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.