Mixing, Blending & Industrial Batch Processing worked example

Scrap/Reblend Cost at 50% recovered material share: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop recovered material share to 50%, then walk the calculation through step by step. Estimate scrap and reblend cost from off-spec mass, reblend cost rate, recovered material share, and fixed disposal and rework labor.

The inputs for this scenario

  • Off-spec batch mass: 180 kg (held at the documented default)
  • Reblend cost rate: 2.2 $ / kg (held at the documented default)
  • Recovered material share: 50 % (the input this scenario stresses; the baseline uses 70)
  • Disposal and rework labor: 120 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Scrap or reblend cost = off-spec mass × reblend cost rate × recovered material share + disposal and rework labor.
  • Weighted cost works out to 318 $ / batch at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 1.77 $ / piece at these inputs.
  • Captured value works out to 198 $ at these inputs.
  • Fixed adjustment works out to 120 $ at these inputs.

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 19.94% below the baseline at 318 $ / batch.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to recovered material share, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 318 $ / batch (headline result)
  • Per piece value: 1.77 $ / piece
  • Captured value: 198 $
  • Fixed adjustment: 120 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Scrap/Reblend Cost calculator, set recovered material share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.