Sizing Batch Washout & Size Box Changeover Optimizer

The formula

This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.

How the result is derived

Step by step, from the values you type to the figure on screen.

1. The 7 inputs are read from the form on every keystroke: Size Box Volume, Fresh Size Addition Rate, Size Liquor Value, Recipe Difference, Acceptable Deviation, Drain and Clean Time and Refill and Heat-up Time.
2. Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
3. The validated values are substituted into the expression above, which resolves Displacement Time together with every supporting figure in one pass — no value is carried over from a previous entry.
4. The supporting outputs — Box Turnovers Required, Volume to Displace, Drain and Refill Time, Time Saved by Displacing and Size Liquor Not Discarded — come from the same pass, so they always describe the same case as the headline figure.
5. Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.

What each input means

Where to read each value on the floor, the unit it must be in, and the range the tool accepts.

What the tool returns

The headline figure and every supporting value it is built from.

Worked example

The tool loads with this case already solved — the Displacement Time shown above is its answer. Change one value and the difference from this baseline is the sensitivity of the result to that variable.

How to use it

1. Work through the input groups in order — Size Box and Recipe Change. The defaults are a realistic case, so you can change one value at a time and watch what moves.
2. There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
3. Read Displacement Time in the dark results panel — that is the headline figure, expressed in h.
4. Check the supporting rows underneath (Box Turnovers Required, Volume to Displace, Drain and Refill Time, Time Saved by Displacing and Size Liquor Not Discarded) before acting on the headline — they are where an implausible input usually shows itself first.
5. Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.

Where this is used

• Process planning — establishing Displacement Time before a trial is booked, so machine time and material in Production Planning & Sequencing are committed against a calculated figure rather than an estimate.
• Costing and quotation — Displacement Time is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
• Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Size Box Volume) shows how much of the gap in Displacement Time each variable explains.
• Teaching and study — the accepted ranges bracket normal Production Planning & Sequencing practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.

Assumptions and limits

• Displacement is only available when both recipes are chemically compatible, and that is a formulation judgement rather than an arithmetic one — mixing incompatible binders can gel the box, which costs far more than the drain it was avoiding. A negative time saving simply means draining is quicker for this pair. The exponential also assumes the box is well stirred and the addition is fresh recipe at working concentration; boxes with poor circulation retain old size in corners and on immersed rollers. Whatever the sequence, the yarn made during the transition carries an intermediate size add-on and should be tracked, since weaving performance follows size pick-up closely.
• Every input is bounded to the range normal practice occupies (Size Box Volume 50 to 5000 L, Fresh Size Addition Rate 20 to 3000 L/h and Size Liquor Value 0.05 to 20 /L, and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
• The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
• Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.

Questions people ask