Paint, Resin & Polymer Compounding worked example

Batch Scale-Up Risk with scale-up severity score of 15 score: a worked example

What does the result look like when scale-up severity score reaches 15 score? The full calculation is worked below with real intermediate numbers. you need to rank scale-up risks for resin and coating batches before committing the first full production run

The inputs for this scenario

  • Scale-up severity score: 15 score (raised for this scenario; the documented default is 6)
  • Occurrence likelihood score: 4 score (unchanged)
  • Detection difficulty score: 3 score (unchanged)

Working through the calculation

  • Applying the documented formula (Batch scale-up risk score = severity * 0.4 + occurrence likelihood * 0.35 + detection difficulty * 0.25) to the inputs above produces each figure below.
  • At this operating point the engine returns 8.15 score for batch scale-up risk score, the number this scenario is built around.
  • At this operating point the engine returns 15 score for scale-up severity score.
  • At this operating point the engine returns 4 score for occurrence likelihood score.
  • At this operating point the engine returns 3 score for detection difficulty score.

How this compares with the baseline

  • Against the tool's baseline example, where scale-up severity score sits at 6 score and the headline result is 4.55 score, this scenario comes in 79.12% above the baseline at 8.15 score.
  • A figure at this level is achievable when scale-up severity score is genuinely sustained, not just peaked for a shift. Scores are subjective inputs; the number is only meaningful if the same team uses a consistent scale across every batch it compares.

Results at a glance

  • Batch scale-up risk score: 8.15 score (headline result)
  • Scale-up severity score: 15 score
  • Occurrence likelihood score: 4 score
  • Detection difficulty score: 3 score

Run it with your numbers

  • Every input above is editable in the live Batch Scale-Up Risk calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.