Manage yield and loss and batch size

Yield and loss percentages ensure accurate material requirements planning by accounting for processing efficiency and material losses during production.

Configure yield and loss parameters

To configure formulation yield, follow these steps:

1. Select the Search icon , enter Formulations, and then choose the related link.
   The Formulations page opens.
2. Select the required Formulation No. field value to open an existing formulation.
   The Formulation page opens.

3. On the Output FastTab, enter the required information in the Yield % field.
   Enter the expected overall yield of the formulation batch as a percentage of output versus input. For example, enter 95 if you expect 5% loss during processing. The value must be between 0 and 100.

   When you enter a yield percentage, the system automatically calculates the adjusted output quantity using the formula:

   Adjusted output quantity = Output Quantity × (Yield % ÷ 100).

   This adjusted quantity represents the actual expected output after accounting for processing losses.

   The yield percentage affects cost calculations in the Cost Analysis page by increasing the effective cost per unit of output. For more information, see Cost rollup analysis.

4. On the Lines FastTab, configure loss percentages for individual ingredients.

   Loss %: Enter the expected loss (scrap) percentage for this ingredient during processing.

   The system uses the loss percentage to calculate the gross quantity from the net quantity using the formula:

   Gross Quantity = Net Quantity ÷ (1 - Loss % ÷ 100).

   For example, if the net quantity is 100 kg and the loss percentage is 5%, the gross quantity becomes 105.26 kg (100 ÷ 0.95).

Scale formulation batch sizes

Formula scaling enables proportional adjustment of all ingredient quantities when changing batch sizes, maintaining recipe integrity while accommodating different production requirements.

To scale a formulation, follow these steps:

1. On the Formulation page, on the action bar, select Scale formula.
   The Scale formula dialog opens.

2. In the New output quantity field, enter the desired batch size for the scaled formulation.
   The system calculates the scaling factor using the formula:

   Scaling Factor = New Output Quantity ÷ Current Output Quantity.

3. Select OK to apply the scaling operation.

The system performs the following scaling operations:

• Ingredient scaling: All ingredient active quantities are multiplied by the scaling factor. The system recalculates net and gross quantities based on the new active quantities, maintaining potency and loss percentage relationships.
• Phase/operation scaling: Phase operations scale according to their configured scaling method:
  • Proportional scaling: Setup time, run time, wait time, and move time are multiplied by the scaling factor. This is appropriate for operations where processing time correlates directly with batch size, such as mixing or heating operations.
  • Fixed scaling: All operation times remain constant regardless of batch size changes. This is appropriate for operations like quality checks, equipment setup, or cleaning procedures that require the same time regardless of batch quantity.

The system presents a scaling preview page that shows current and scaled run times for all phase operations, allowing users to review and confirm scaling decisions before applying changes.

To scale a formulation version, follow these steps:

1. Select the Search icon , enter Formulation Versions, and then choose the related link.
   The Formulation Versions page opens.
2. Select the required version to open the Formulation version card page.
3. On the action bar, select Scale Formula.
4. Enter the New output quantity and select OK.

The scaling process for formulation versions follows the same logic as formulation headers, ensuring consistency across all formulation development stages.