Nutraceuticals & Functional Foods worked example

Capacity Gap at 61% expected line uptime: a worked example in nutraceuticals & functional foods

Here is what the math looks like when conditions slip. We hold every other input steady and drop expected line uptime to 61%, then walk the calculation through step by step. Estimate the good production capacity available over a period so planners can compare it against demand and see the capacity gap before committing.

The inputs for this scenario

  • Output per production day: 50,000 units / day (held at the documented default)
  • Available production days: 20 days (held at the documented default)
  • Expected line uptime: 61 % (the input this scenario stresses; the baseline uses 85)
  • Expected first-pass yield: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity = output per production day × available production days.
  • Good capacity available works out to 585,600 units at these inputs, and this is the headline figure for the scenario.
  • Gross capacity works out to 1,000,000 units at these inputs.
  • Capacity lost to downtime works out to 390,000 units at these inputs.
  • Capacity lost to yield works out to 24,400 units at these inputs.

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 28.24% below the baseline at 585,600 units.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to expected line uptime, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It applies single average uptime and yield figures, so it will not capture line-specific bottlenecks, SKU mix effects, or batch-record hold time before QA release.

Results at a glance

  • Good capacity available: 585,600 units (headline result)
  • Gross capacity: 1,000,000 units
  • Capacity lost to downtime: 390,000 units
  • Capacity lost to yield: 24,400 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Capacity Gap calculator, set expected line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.