Is this the total inventory loss?

No, it is the additional spending after an off-spec batch already exists. Original batch cost is excluded because it is unchanged between these options.

Which recovered mass should I enter?

Enter original off-spec material retained in usable output. Exclude virgin ingredients added during reblend; include their purchase cost in reblend spending.

What replacement value is appropriate?

Use the purchase spending actually avoided by usable recovered material. Enter zero when no approved replacement use exists.

Where do testing and disposal fees go?

Put additional testing in reblend spending and variable disposal charges in the disposal rate. Include reblend-only fixed handling separately; common fixed disposal charges cancel.

Mixing, Blending & Industrial Batch Processing calculator

Scrap Reblend Cost Calculator

Cost a proposed reblend and the material still requiring disposal. Enter original and recovered masses, incremental spending, disposal rate, replacement value and reblend-only handling.

What this calculator does

Calculate incremental reblend and disposal spending, then compare recovered replacement value with scrapping the entire off-spec batch.

Formula used

Unrecovered mass = original mass − recovered original mass
Reblend cost = reblend spending + unrecovered mass × disposal rate + handling
Cost per kilogram = reblend cost ÷ original mass; recovery = recovered ÷ original × 100
Avoided purchases = recovered mass × replacement value
Net benefit = recovered mass × (replacement value + disposal rate) − reblend spending − handling

Inputs explained

Original Off-Spec Mass: Weighed original batch mass placed on quality hold.
Recovered Original Material: Original material released after reblend, excluding newly added ingredients.
Incremental Reblend Spending: Additional ingredients, labor, energy, tests and constrained-capacity cost.
Variable Disposal Rate: Disposal invoice charge per kilogram of unrecovered material.
Approved Replacement Value: Avoided purchase cost for each usable recovered original kilogram.
Reblend-Only Handling Cost: Additional handling incurred only when choosing the reblend option.

How to use the result

Best suited to off-spec batch disposition, approved recovery comparison.
Does not approve reblend chemistry or predict recovered mass. Excludes original batch spending already incurred under either option.

Common questions

Is this the total inventory loss? No, it is the additional spending after an off-spec batch already exists. Original batch cost is excluded because it is unchanged between these options.
Which recovered mass should I enter? Enter original off-spec material retained in usable output. Exclude virgin ingredients added during reblend; include their purchase cost in reblend spending.
What replacement value is appropriate? Use the purchase spending actually avoided by usable recovered material. Enter zero when no approved replacement use exists.
Where do testing and disposal fees go? Put additional testing in reblend spending and variable disposal charges in the disposal rate. Include reblend-only fixed handling separately; common fixed disposal charges cancel.

Last reviewed 2026-10-01.