Manage BOP > Enterprise Recipe Management (ERM)

Understanding batch calculations

Batch calculations are used to scale a master recipe size up or down.

The manufacturing formula is derived by scaling formula quantities by batch size. The formula is similar to a manufacturing bill of materials (MBOM) when you customize work package structure names for an ERM recipe work package.

The formula is the product design specification that defines the recipe for one unit or SKU—for example, 100 grams beverage composition.
The manufacturing formula is the manufacturing specification that defines the recipe—for example, 500 units. 100 grams x 500 = 50,000 grams total.

The batch size is based on the selected mass unit for the formula. SKU units are a simple number, formula units are based on mass—kilograms, grams, pounds, and so on. Structure configuration options include the following.

Define batch size at the top root node level of the Item SKU hierarchy. Batch Size (units) └── Item SKU TOP └── Formula_Material_Top └── Flavor_Blend └── Water
Define batch size at the top root node level of the Formula Material hierarchy. Batch Size (grams, kilograms, pounds) └── Formula_Material_Top └── Flavor_Blend └── Water

Calculations, as shown in the example below, help you to translate batch requirements into precise quantities for every ingredient, and to support efficient planning as you scale recipes up or down. Using this structured approach, you can consistently make products to required standards despite changes in batch size.

The batch size, represented as A, is the number of units you want to produce. In this example, the batch size is 500 units.
A * B calculates the total formula mass needed for the batch. Number of units (500) multiplied by the formula mass (100) for one unit equals 50,000.
C * D / 100 calculates how much of the base consumable is needed for the whole batch. Total manufacturing formula mass (50,000) multiplied by the base weight percentage (70) equals 3,500,000. 3,500,000 divided by 100 equals 35,000, the correct amount in grams.Note You can alternately convert the percentages to decimals, for example, 70 = .7, to avoid dividing by 100. Total manufacturing formula mass (50,000) multiplied by the base weight percentage (.7) equals 35,000.
E * F / 100 determines how much milk is required, using the base mass and the percentage of milk in the mix. 35,000 multiplied by 65 equals 2,275,000. Divided by 100, the required amount of milk equals 22,750 grams.
E * G / 100 repeats the same calculation for water, multiplying the base mass by the water percentage.
C * H / 100 calculates the total mass of the flavor blend needed for the batch.
The flavors coffee, sugar, and vanilla (I * J / 100, I * K / 100, and I * L / 100) start with the total flavor blend mass (15,000) multiplied by the percentage for each flavor ingredient. For example, for I * J / 100, 15,000 multiplied by 40 equals 600,000. Divided by 100, the required amount of coffee equals 6,000 grams.