Mixing, Blending & Industrial Batch Processing worked example

Scrap/Reblend Cost at 81% recovered material share: a worked example

What does the result look like when recovered material share reaches 81%? The full calculation is worked below with real intermediate numbers. Use it when an off-spec batch needs a rework or disposal call and you need to compare reblend cost against scrap and rerun cost before deciding.

The inputs for this scenario

  • Off-spec batch mass: 180 kg (unchanged)
  • Reblend cost rate: 2.2 $ / kg (unchanged)
  • Recovered material share: 81 % (raised for this scenario; the documented default is 70)
  • Disposal and rework labor: 120 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Scrap or reblend cost = off-spec mass × reblend cost rate × recovered material share + disposal and rework labor) to the inputs above produces each figure below.
  • At this operating point the engine returns 441 $ / batch for weighted cost, the number this scenario is built around.
  • At this operating point the engine returns 2.45 $ / piece for per piece value.
  • At this operating point the engine returns 321 $ for captured value.
  • At this operating point the engine returns 120 $ for fixed adjustment.

How this compares with the baseline

  • Against the tool's baseline example, where recovered material share sits at 70% and the headline result is 397 $ / batch, this scenario comes in 10.97% above the baseline at 441 $ / batch.
  • A figure at this level is achievable when recovered material share is genuinely sustained, not just peaked for a shift. It treats the recovered-material share as a simple discount on reblend cost and does not model downstream yield loss, lab retest cost, or value lost if reblended product is downgraded to a lower-margin grade.

Results at a glance

  • Weighted cost: 441 $ / batch (headline result)
  • Per piece value: 2.45 $ / piece
  • Captured value: 321 $
  • Fixed adjustment: 120 $

Run it with your numbers

  • Every input above is editable in the live Scrap/Reblend Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.