Thermal Spray, Hardfacing & Wear Coatings worked example

Batch Throughput at 65% spray-line efficiency: a worked example in thermal spray, hardfacing & wear coatings

Suppose spray-line efficiency falls to 65%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Batch Throughput measures how many coated parts a thermal spray booth actually delivers per hour once real-world efficiency losses are applied.

The inputs for this scenario

  • Parts coated in the run: 1,200 units (held at the documented default)
  • Booth runtime for the batch: 8 hr (held at the documented default)
  • Spray-line efficiency (uptime vs. scheduled): 65 % (the input this scenario stresses; the baseline uses 90)

Working through the calculation

  • The calculation starts from the formula this tool documents: Raw batch throughput = completed output รท runtime.
  • Effective throughput works out to 97.5 units / hr at these inputs, and this is the headline figure for the scenario.
  • Raw throughput works out to 150 units / hr at these inputs.
  • Efficiency works out to 65 % at these inputs.
  • Runtime works out to 8 hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where spray-line efficiency sits at 90% and the headline result is 135 units / hr, this scenario comes in 27.78% below the baseline at 97.5 units / hr.
  • It divides completed output by runtime for a raw rate, then multiplies by an efficiency factor to give effective parts coated per hour. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Effective throughput: 97.5 units / hr (headline result)
  • Raw throughput: 150 units / hr
  • Efficiency: 65 %
  • Runtime: 8 hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Batch Throughput calculator, set spray-line efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.