Reconcile theoretical vs. actual powder or granule weight after granulation and drying.
Granulation reconciliation is one of the first material-balance checks in a tablet or capsule manufacturing process, run right after wet or dry granulation and drying. Comparing the theoretical weight expected from the batch formula against the weight of powder or granules actually recovered tells you, in a single number, how much material was lost to equipment holdup, dust collection, or spillage before the batch even reaches compression or encapsulation.
Because granulation losses compound into every later stage — compression, coating, encapsulation — catching an unusually large loss here, before further processing, is far cheaper than discovering it after tablets have already been compressed or coated.
This calculator lets you label the material as powder or granules purely for record-keeping, since the underlying weight-based calculation is identical either way.
Granulation is where a batch first commits to its final form, and it's also one of the more variable steps in solid dosage manufacturing — fines generation, equipment surface adhesion, and dryer losses all chip away at the theoretical yield before anything reaches a tablet press or capsule filler.
Common causes include material adhering to mixer or granulator surfaces, fines lost to the dust collection system, and spillage during transfer to the dryer or holding containers.
Divide the actual weight of powder or granules recovered by the theoretical weight expected from the batch formula, then multiply by 100.