Nutraceuticals & Functional Foods worked example

Capacity Gap at 98% expected line uptime: a worked example in nutraceuticals & functional foods

Push expected line uptime up to 98% and the picture changes. This example computes every intermediate figure at that operating point. A planner needs the realistic good output a process can deliver over a period to compare against demand and size any capacity shortfall.

The inputs for this scenario

  • Output per production day: 50,000 units / day (unchanged)
  • Available production days: 20 days (unchanged)
  • Expected line uptime: 98 % (raised for this scenario; the documented default is 85)
  • Expected first-pass yield: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross capacity = output per production day × available production days) to the inputs above produces each figure below.
  • At this operating point the engine returns 940,800 units for good capacity available, the number this scenario is built around.
  • At this operating point the engine returns 1,000,000 units for gross capacity.
  • At this operating point the engine returns 20,000 units for capacity lost to downtime.
  • At this operating point the engine returns 39,200 units for capacity lost to yield.

How this compares with the baseline

  • Against the tool's baseline example, where expected line uptime sits at 85% and the headline result is 816,000 units, this scenario comes in 15.29% above the baseline at 940,800 units.
  • It computes good sellable units as gross capacity multiplied by expected uptime and expected yield, and splits out the units lost to each. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Good capacity available: 940,800 units (headline result)
  • Gross capacity: 1,000,000 units
  • Capacity lost to downtime: 20,000 units
  • Capacity lost to yield: 39,200 units

Run it with your numbers

  • Every input above is editable in the live Capacity Gap calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.