Recalculate ingredient quantities

Dynamic Production  •  Article  •  10/22/2025  • 

You can automatically recalculate ingredient quantities based on the actual potency of assigned lots to ensure the target potency is achieved. This process is only available for production orders in firm planned status.

Recalculating a single lot

For single-lot assignments, the system uses the formula:

Required Quantity = (Target Potency / Lot Potency) × Original Quantity

For example, if a formula calls for 10 kg at 100% potency and a lot with 80% potency is assigned, the system updates the required quantity as 12.5 kg (10 × 100/80).

Conversely, if a lot with 120% potency is assigned, the required quantity is reduced to approximately 8.33 kg (10 × 100/120).

Recalculate multiple lots

For multi-lot assignments, the system calculates the adjusted required quantity for each lot to ensure the total active ingredient meets the formula requirement.

The system distributes the total active requirement across lots based on:

  • Initial allocation proportions
  • Available lot quantities
  • Potency variance from target

For example two lots requiring 50 active units:

  • Lot A: 85% potency
  • Lot B: 95% potency

The system apportions the load so that the weaker lot contributes more weight and the stronger lot less, ensuring the combined active content equals the required 50 units.

Each lot's quantity is computed as: (Target Potency / Lot Potency) × Initial Allocation

Compensating and filler ingredients

When the actual potency of an active ingredient differs from the standard (target) potency, the system automatically adjusts the quantities of related components to maintain the intended formula balance and total batch size. These adjustments depend on the type of relationship the component has with the active ingredient.

  • Dependent ingredients (Fixed Ratio): Adjusted according to their defined ratio to maintain the specified proportion.
    • For example: If active increases by 20%, a dependent with a 1:4 ratio also increases by 20%.
  • Filler ingredients (Balance to Total): Inversely adjusted to maintain total batch size.
    • For example: If active increases by 5 mg, filler decreases by 5 mg to keep tablet weight constant.

The system ensures that tablet mass or batch weight remains constant while achieving correct active content.

Adjust relationship sequence

The system processes adjustments in the following order:

  • Adjust active ingredient quantities based on lot potency
  • Adjust dependent ingredients with fixed ratio relationships
  • Adjust filler ingredients to maintain total batch weight
    • Validate that all relationships are satisfied

This prevents circular or oscillating adjustments.

The production document is created with potency validation applied.

Release a production document

You can release production documents after the system validates all potency requirements.

The system performs the following validations before releasing:

  • Potency-controlled components have valid lot assignments
  • Calculated quantities achieve target potency specifications
  • Dependent ingredient relationships are satisfied
  • Quality control requirements are met (if configured)

When posting a production document, the system performs final validation and records actual potency achievements.