Ingredient types
A formula line that is created can have one of the following ingredient types:
None
Active
Compensating
Filler
The rest of this section provides examples that show how each ingredient type works. The examples are based on the following formula that has a total batch size of 100 liters.
| Ingredient type | Item number | Formula line quantity | Unit |
|---|---|---|---|
| None | A | 20 | Liter |
| Active | B | 30 | Liter |
| Compensating | C | 10 | Liter |
| Filler | D | 40 | Liter |
Active
When a product that has a base attribute is added to a formula line, it's referred to as an active ingredient of the formula. Batch orders that have formulas that include active ingredients can be used for the batch balancing process. For each ingredient in the formula, the batch balancing process estimates the amount that is required to produce the product. The estimate of amounts is based on the concentration of active ingredients in the selected batches.
Example
Ingredient B has base attribute X and a target level of 30, and it's included in a formula that requires 30 liters of Ingredient B for every 100 liters of the product. A batch order is created that has a batch size of 100 liters. The batch order is started, and during the batch balancing process, the user selects a batch of Ingredient B that has a potency level of 35. Because the potency level of 35 is higher than the target level of 30, the balanced quantity of Ingredient B is reduced by using the ratio of the potency value to the target level of the batch, which is multiplied by the estimated quantity.
The calculation of the balanced quantity looks as follows:
(30 ÷ 35) × 30 liters = 25.71 liters
| Item number | Ingredient type | Estimated quantity | Balanced quantity | Active quantity | Unit | Base value |
|---|---|---|---|---|---|---|
| A | None | 20 | 20 | Liter | ||
| B | Active | 30 | 25.71 | 9.00 | Liter | 30.00 |
| C | Compensating | 10 | 14.72 | Liter | ||
| D | Filler | 40 | 39.57 | Liter |
None
When you apply the batch balancing process when the ingredient type is None, the estimated quantity and the balanced quantity of the formula line in the batch order are the same.
Example
Ingredient A is assigned to an ingredient of the None type and added to a formula for a finished product. The formula requires 10 liters of Ingredient A for every 100 liters of the finished product. When a batch order requires 200 liters, the estimated quantity and the balanced quantity of Ingredient A are calculated as 20 liters.
Compensating
A compensating ingredient can either offset or complement the effect of the active ingredient in a product. Therefore, the quantity of a compensating ingredient that is consumed depends on the potency of the product:
Opposing effect - If the amount of the active ingredient is more than anticipated, you must add less of the compensating ingredient.
Complementary effect - If the amount of the active ingredient is less than anticipated, you must add more of the compensating ingredient.
The relation between an active ingredient and a complementary ingredient is set up on the Compensating principle page.
Follow these steps to set up relations between ingredients:
Select Product information management > Bills and materials and formulas > Formulas, open a formula line, and then select Ingredients to open the Compensating principle page.
Select the line that represents a compensating principle, and then select the active ingredient to compensate.
In the compensating principle, you can also enter a positive or negative compensating factor to specify how much to compensate for and whether the principle should be opposing or complementary. A positive factor indicates a complementary effect, and a negative factor indicates an opposing effect.
Example
Ingredient B is an active ingredient that has base attribute X and a target level of 30. It's included in a formula that requires 30 liters of Ingredient B for every 100 liters of the product. Ingredient C is a compensating ingredient, and a quantity of 10 is included in the same formula. A compensating factor of 1.10 is set up for the compensating principle. Therefore, the balanced quantity of the compensating ingredient will be reduced by the difference between the active ingredient's balanced quantity and the estimated required quantity multiplied by 1.10.
In the example for the Active ingredient type, the balanced quantity of the required active ingredient was calculated as 25.71, and the estimated required quantity was calculated as 30. In this case, the balanced quantity of the compensating ingredient will be calculated as follows:
The difference between the estimated and the balanced quantity is determined:
25.71 - 30 = -4.29
The result is multiplied by the compensating factor:
-4.29 × 1.10 = -4.72
The estimated compensating quantity is reduced by -4.72 to determine the balanced compensating quantity:
10 - (-4.72) = 14.72
Because 1.10 is a positive compensating factor, this compensating principle has a complementary effect. In this case, the active ingredient is more potent than anticipated. Therefore, more of the compensating ingredient is required.
Filler
A filler ingredient is a neutral ingredient that is used to reach the desired output quantity of the finished product. Adjustments to filler quantities are calculated based on variations in the active ingredient and the compensating ingredient compared to the standard quantity.
Example
You've formulated a product that includes ingredients A, B, C, and D for a formula size of 100 liters. You've calculated the balanced quantity of all the ingredient types except the Filler ingredient type that is used on one line. The balanced quantity of the filler ingredient is calculated as the difference between the batch size of 100 liters and the sum of ingredients A, B, and C:
100 - (20 + 25.71 + 14.72) = 39.57