Mixing, Blending & Industrial Batch Processing worked example

Scale-Up Ratio with pilot batch size of 10 L: a worked example

This worked example runs the scale-up ratio numbers for a tougher week than the baseline: pilot batch size of 10 L instead of the typical 20 L. Translate a pilot batch into a production batch size using scale-up factor, geometric correction, and a process efficiency multiplier.

The inputs for this scenario

  • Pilot batch size: 10 L (the input this scenario stresses; the baseline uses 20)
  • Scale-up factor: 100 x (held at the documented default)
  • Geometric correction: 0.95 x (held at the documented default)
  • Process efficiency multiplier: 0.97 x (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Production batch size = pilot batch size × scale-up factor × geometric correction × process efficiency multiplier.
  • Result works out to 922 L / batch at these inputs, and this is the headline figure for the scenario.
  • Base product works out to 950 value at these inputs.
  • Multiplier works out to 0.97 x at these inputs.
  • Factor A x B works out to 1,000 value at these inputs.

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 50% below the baseline at 922 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. 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

  • Result: 922 L / batch (headline result)
  • Base product: 950 value
  • Multiplier: 0.97 x
  • Factor A x B: 1,000 value

Run it with your numbers

  • To rerun this with your own numbers, open the live Scale-Up Ratio calculator, set pilot batch size to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.