Mixing, Blending & Industrial Batch Processing worked example
Throughput Per Shift at 98% line utilization: a worked example in mixing, blending & industrial batch processing
What does the result look like when line utilization reaches 98%? The full calculation is worked below with real intermediate numbers. Use it when you are committing a shift output number to S&OP and need an honest throughput rate the line can actually hold, not the SOP cycle math.
The inputs for this scenario
- Completed batch output: 9,000 kg (unchanged)
- Mixer runtime in shift: 8 hr (unchanged)
- Line utilization: 98 % (raised for this scenario; the documented default is 85)
Working through the calculation
- Applying the documented formula (Raw throughput = completed batch output รท mixer runtime in shift) to the inputs above produces each figure below.
- At this operating point the engine returns 1,103 kg / hr for effective throughput, the number this scenario is built around.
- At this operating point the engine returns 1,125 kg / hr for raw throughput.
- At this operating point the engine returns 98 % for efficiency.
- At this operating point the engine returns 8 hr for runtime.
How this compares with the baseline
- Against the tool's baseline example, where line utilization sits at 85% and the headline result is 956 kg / hr, this scenario comes in 15.29% above the baseline at 1,103 kg / hr.
- A figure at this level is achievable when line utilization is genuinely sustained, not just peaked for a shift. It treats utilization as a single average percentage, so it won't surface intermittent bottlenecks, micro-stoppages, or variation between batch types within the shift.
Results at a glance
- Effective throughput: 1,103 kg / hr (headline result)
- Raw throughput: 1,125 kg / hr
- Efficiency: 98 %
- Runtime: 8 hr
Run it with your numbers
- Every input above is editable in the live Throughput Per Shift calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.