Batch Sizes

Why is Batch Size Important in Liquid Manufacturing?

In liquid manufacturing, a batch size is the total quantity of product produced during a single production run. It is typically influenced by blending tank capacity, raw material availability, equipment configuration, and production scheduling.

Selecting the correct batch size is essential for maintaining efficiency, product quality, and profitability. Oversized batches can lead to excess inventory and reduced flexibility, while undersized batches may increase per-unit costs and require more frequent changeovers. Factors such as raw material minimums, ingredient packaging formats, shift length, and cleaning requirements also influence how batches are structured.

Optimizing batch size helps ensure productive runs, controlled costs, and a responsive supply chain.

What are PCI’s Batch Size Capabilities?

PCI supports batch sizes ranging from 100 to 3,000 gallons, providing meaningful flexibility for short run liquid manufacturing, pilot production, multi-SKU programs, and scaled commercial volumes.

Our blending infrastructure includes:

• 500 gallon tank – 1 unit
• 1,000 gallon tank – 1 unit
• 2,000 gallon tank – 1 unit
• 3,000 gallon tanks – 2 units

This range of tank sizes allows PCI to align production volumes with customer forecasts, packaging configurations, and growth strategies. Smaller batch capabilities help customers reduce inventory risk and support specialty programs, while larger tanks enable efficient scale-up without changing manufacturing partners.

By offering flexible batch sizes from 100 to 3,000 gallons, PCI helps customers optimize liquid contract manufacturing programs for efficiency, scalability, and long-term profitability.