Paint, Resin & Polymer Compounding worked example

Batch Blend Time at 23% charging, grind, and letdown time allowance: a worked example

What does the result look like when charging, grind, and letdown time allowance reaches 23%? The full calculation is worked below with real intermediate numbers. you need a defensible blend time before scheduling the disperser or confirming a batch fits the available shift

The inputs for this scenario

  • Batch size to blend: 1,000 gal (unchanged)
  • Disperser throughput rate: 12 gal / min (unchanged)
  • Charging, grind, and letdown time allowance: 23 % (raised for this scenario; the documented default is 20)

Working through the calculation

  • Applying the documented formula (Base blend time = batch size / disperser throughput rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 102 hr for required blend time, the number this scenario is built around.
  • At this operating point the engine returns 83.33 hr for base blend time.
  • At this operating point the engine returns 23 % for charging, grind, and letdown allowance.
  • At this operating point the engine returns 12 pieces / min for disperser throughput rate.

How this compares with the baseline

  • Against the tool's baseline example, where charging, grind, and letdown time allowance sits at 20% and the headline result is 100 hr, this scenario comes in 2.5% above the baseline at 102 hr.
  • A figure at this level is achievable when charging, grind, and letdown time allowance is genuinely sustained, not just peaked for a shift. The single allowance percentage lumps charging, grind, and letdown together — highly loaded or hard-to-disperse pigment systems may need a much larger allowance than free-flowing letdown-heavy formulas.

Results at a glance

  • Required blend time: 102 hr (headline result)
  • Base blend time: 83.33 hr
  • Charging, grind, and letdown allowance: 23 %
  • Disperser throughput rate: 12 pieces / min

Run it with your numbers

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

Last reviewed 2026-05-12.