How Much Spare Production Capacity Should I Keep for Breakage, Rejected Candles and Remakes When Promising a Bulk-Order Deadline?
Aktie
How do I express it? As two dates. Plan to finish on day 24 (the internal target); promise the client day 26. The naive sum, 1,500 ÷ 100, would have promised day 17.
Is two days enough? It absorbs one bad thing: a lost day, a reject rate double your history, or a late remake. Two bad things land exactly on the client date. A late material delivery misses it, which is why materials are confirmed before day 1.
Does it change what I buy? The time buffer and the material buffer must match: 1,590 pours of wax and oil (extras and 5% loss inside), 1,622 jars and wicks with 2% breakage. CSI materials: ₹3,91,222.00.
- Straight answer: how much spare to keep
- The order and your real rate, as numbers
- Building the buffer, part by part
- Two dates: the internal target and the promise
- Stress-test the promise before you make it
- Material buffers that match the time buffer
- Guarding the buffer
- What to buy, and how much spare
- Frequently asked questions
The order and your real rate, as numbers
| Input | Figure | Note |
|---|---|---|
| Saleable candles | 1,500 | The wedding order |
| Fill and load | 150 g at 8% = 12 g oil + 138 g wax | Clear Glass Jar with Golden Lid (150 gram): page states "150g fill capacity" |
| Demonstrated rate | 100 candles a day | Wick, pour, QC, lid, label, pack, all included |
| Planned extras | 15 | Client samples, QC retains, burn checks (1%) |
| Historical reject rate | 5% | Sinkholes, off-centre wicks, chips, label errors |
| Pours | 1,590 = 1,500 + 15 + 75 | Expected rejects poured up front, not remade later |
| Base production days | 16 (15.90) | 1,590 ÷ 100 |
| Set-up and tail | 2 + 3 working days | Sample, PO, materials in; 72 h set, final QC, pack |
| Week | 6 working days, day 1 a Monday | Calendar day = working day + Sundays passed |
"Demonstrated" matters. A maker who poured 140 on her best day and averages 100 over a normal week has a rate of 100. Plan on the best day and the buffer is spent before the first problem. If you have never run five consecutive production days at this jar and this fill, time a trial before you promise anything (the timed-trial capacity post).
The naive count, 1,500 ÷ 100 = 15 days, forgets extras and rejects (90 more pours), set-up, the set and the pack, and the bad day. It would put the hand-over on day 17: nine days early on paper and impossible in practice.
Building the buffer, part by part
The commonest mistake is to add a percentage for rejects to the pours and another percentage to the days for the same rejects. The table separates what is counted where.
| Risk | How big (worked example) | Covered by | Days it adds | Why there |
|---|---|---|---|---|
| Expected rejects | 5% = 75 pours | Pour count | 0.75 (inside the 16) | You know it will happen; pour it while the melter is hot, same lot |
| Planned extras | 15 pours | Pour count | 0.15 (inside the 16) | Samples and retains are part of the job |
| In-house breakage | 2% of jars and wicks | Spare pieces | none | A broken jar is replaced from the shelf, poured with the next melt |
| Defects found late | 2% = 30 candles at final QC or packing | Time: remake day | 1 | A remake needs a new 4.54 kg melt and its own 72 h set |
| A lost day | power, illness, a melter fault | Time: lost-day allowance | 1 | One per about two weeks of pouring (judgement) |
| Time buffer | 2 days | 12.5% of 16 production days |
Why is the remake day separate from the reject pours? Because the rejects you find early, at each day's QC after the 72-hour set, are replaced from the loss-buffer pours already made. The ones you find on the last days, in final QC, packing or a dropped carton, have nothing left to replace them from, and a candle poured today is not ready for three days. The remake day is where those 30 get poured, early enough to set inside the tail. Its material is about ₹7,234.99 at bulk prices; its real cost is the day.
To size your own, work through it in this order, with your records beside you:
Two dates: the internal target and the promise
Lay it out in working days, then convert: 2 set-up + 16 production + 3 tail = 21 working days, calendar day 24. Add the 2 buffer days and it is 23 working days, calendar day 26. The first is the internal target on the workshop wall; the second is the date in the client's purchase order.
| Block | Working days | Calendar days | What happens |
|---|---|---|---|
| Set-up | 1–2 | 1–2 | Signed sample, PO and advance, materials in and checked |
| Production | 3–18 | 3–20 | 1,590 pours at 100 a day; daily QC from day 6 after each 72 h set |
| Buffer | 19–20 | 22–23 | Remake day and lost-day allowance; if unused, the tail moves up |
| Tail | 21–23 | 24–26 | 72 h set on the last pours, final QC, cartons, hand-over |
| Internal target | 21 | day 24 | Buffer unused |
| Client date | 23 | day 26 | Buffer fully used |
Run the workshop to day 24. Track it daily: candles poured against the plan, rejects against 5%. When you fall behind, you know on the day which part of the buffer you are spending, and you can still choose overtime before the buffer is gone. A team that is told the client date works to the client date, and the buffer evaporates in small slips.
Stress-test the promise before you make it
| What goes wrong | Working days | Finish (calendar day) | Against the client date |
|---|---|---|---|
| Nothing: buffer unused | 21 | 24 | 2 days early |
| One production day lost | 22 | 25 | absorbed |
| Rejects at 10% instead of 5% | 22 | 25 | absorbed (and the extra material must exist) |
| 30 late defects remade | 22 | 25 | absorbed by the remake day |
| A lost day and 10% rejects | 23 | 26 | on the date, nothing left |
| Jars arrive 3 days late | 24 | 27 | misses by a day |
Two rows deserve a second look. Rejects at 10% are absorbed in time, but only if the material is there: 75 extra pours need about 11.36 kg more mix, 75 more jars and wicks. Either buy that cover or accept that a doubled reject rate means a short delivery. The late delivery is the one the buffer cannot save, because it pushes every day after it. That is why materials are confirmed in writing before day 1, and why "it usually comes in two days" is not a plan. CSI does not promise dispatch or transit times for bulk quantities; confirm on WhatsApp before you give the client a date.
The decision rule. Promise a date only if it is on or after your internal target plus the time buffer: here, day 26 or later. If the client needs day 24, the honest answers are a smaller first delivery (keeping the buffer, 14 production days fit 1,400 pours, about 1,319 saleable candles), more capacity (a second person, which you must prove with a timed trial), or the rest a few days later. Promising day 24 with no buffer is betting the wedding on nothing going wrong in three and a half weeks.
Material buffers that match the time buffer
The purchase sheet carries the same assumptions as the calendar: 1,590 pours (extras and 5% loss inside), 1% heel, and 2% extra jars and wicks for in-house breakage, which also supplies the remake day. The sheet assumes your proven formula is Luxury Soy Wax Chunks, Japanese Cherry Blossom at 8% and an Eco C1 wick in the Clear Glass Jar with Golden Lid (150 gram).
| Line | For 1,500 saleable | To buy (with buffers) | CSI packs | ₹ | Left over |
|---|---|---|---|---|---|
| Luxury Soy Wax Chunks | 207.0 kg | 221.6142 kg | 22 × 10 kg + 2 × 1 kg = 222 kg | ₹1,33,176.00 | 0.386 kg, reusable |
| Japanese Cherry Blossom | 18.0 kg | 19.2708 kg | 19 × 1 kg + 500 g | ₹94,498.00 | 229.2 g |
| Eco Candle Wicks C1 | 1,500 | 1,622 | 1,000 + 500 + 100 + 20 + 20 = 1,640 | ₹9,676.00 | 18 wicks |
| Clear Glass Jar with Golden Lid (150 gram) | 1,500 | 1,622 | 81 × 20 + 1 × 10 = 1,630 | ₹1,53,872.00 | 8 jars |
| CSI materials | ₹3,91,222.00 | ₹260.81 per saleable candle |
₹260.81 per saleable candle is CSI materials only, buffers included; it excludes labels, cartons, labour, freight, GST and marketing. One poured candle carries about ₹241.17 of CSI materials at these prices, so the 90 extra and loss-buffer pours are about ₹21,704.96: the price of turning "about 1,500" into "exactly 1,500 on time". How rejects and failed batches change your true cost per candle is the true manufacturing cost post; whether wax left in pitchers belongs in that cost is the pitcher-heel post.
Argued against our own interest: nothing in this sheet gets cheaper per unit in a bigger pack. The jar is ₹94.40 in 10s and 20s, C1 is ₹5.90 at every buyable pack, and the Chunks 10 kg bag costs ₹9.00 more than ten 1 kg bags. Buy for the pours, round to the smallest covering packs, and do not "round up for safety" a second time: the buffer is already in the count.
Guarding the buffer
Client changes. A new label proof on day 8, a scent swap on day 10, an extra 100 candles "while you're at it": each eats buffer days the client does not see. Write in the order that changes after sample approval move the date and may carry a fee, and that the date is "calendar day 26 from signed sample and advance". Practical judgement, not legal advice; the advance itself is the advance post.
The never-skip list. The buffer is for remakes and lost days, not for skipping a test. The candle must already be proven in this jar with this wick and oil at 8%, burned to the end; burn-check candles from early and late melts are burned during the run against the approved sample; the last pours get their full set before cartoning. Cutting any of those to rescue a date turns a late order into a bad one (the never-skip post).
Lot changes. If a second lot of jar, wax or oil arrives mid-run, compare it with the first before using it: jar dimensions and lids; wax and oil by cold sniff, colour in wax and a short burn. That check costs part of a day, and it belongs to the buffer only if you planned for it. Ask about lots before day 1 instead.
What to buy, and how much spare
Four items for the worked-example wedding candle, chosen on page statements, price and stock on 7 October 2026. CSI publishes no burn or throw data, so nothing is ranked on performance. Each card says how much spare to carry and when not to buy.
| Pack | Price | Per jar | For this order |
|---|---|---|---|
| Pack of 10 | ₹944.00 | ₹94.40 | the top-up pack |
| Pack of 20 | ₹1,888.00 | ₹94.40 | 81 of these + one 10 = ₹1,53,872.00 |
| Size | Price | Per kg | 150 g candles at 8% (138 g wax) | Note |
|---|---|---|---|---|
| 500 g | ₹299.00 | ₹598.00 | 3 | cheapest per kg |
| 1 kg | ₹599.00 | ₹599.00 | 7 | |
| 5 kg | ₹2,995.00 | ₹599.00 | 36 | same per kg as 1 kg |
| 10 kg | ₹5,999.00 | ₹599.90 | 72 | ₹9.00 more than ten 1 kg |
| Size | Price | Per gram | 150 g candles at 8% |
|---|---|---|---|
| 15 g | ₹104.00 | ₹6.93 | 1 |
| 50 g | ₹270.00 | ₹5.40 | 4 |
| 100 g | ₹500.00 | ₹5.00 | 8 |
| 500 g | ₹2,500.00 | ₹5.00 | 41 |
| 1 kg | ₹4,842.00 | ₹4.84 | 83 |
| Pack | Price | Per wick | For this order |
|---|---|---|---|
| Thin (C1) / 10 | ₹59.00 | — | Out of stock on 7 October 2026 |
| Thin (C1) / 20 | ₹118.00 | ₹5.90 | top-up |
| Thin (C1) / 50 | ₹295.00 | ₹5.90 | |
| Thin (C1) / 100 | ₹590.00 | ₹5.90 | top-up |
| Thin (C1) / 500 | ₹2,950.00 | ₹5.90 | part of 1,640 |
| Thin (C1) / 1,000 | ₹5,900.00 | ₹5.90 | core |
Skip: extra wax "for safety" beyond the sheet (the loss pours are already there), and a second fragrance as a back-up you have never burned in this jar. Argued against our own interest: don't order the 1,630 jars until the client has signed the sample and paid the advance; a buffer on an unconfirmed order is just stock.
CandleMakingSuppliesIndia sells the jars, wax, oil and wicks named here, and does not sell finished candles. This page still tells you that nothing on this sheet is cheaper per unit in a bigger pack, that our 10 kg Chunks bag costs more than ten 1 kg bags, not to round up for safety twice, and not to order jars before the client signs.
Every CSI price was checked on the live store on 7 October 2026, size by size. Every item priced here is in stock on that date; the Eco C1 10-pack is out of stock and is not used. Stock depth, batch continuity and dispatch times for bulk quantities are not published on product pages: confirm them on WhatsApp.
The order, daily rate, extras, reject and breakage rates, late-defect rate, set-up and tail days, lost-day allowance and stress-test delays are labelled worked examples, and the 10–15% band is a judgement, not a statistic; replace them with your records. This is practical business judgement, not legal advice. For bulk pricing, stock confirmation, GST invoicing, and MSDS and IFRA documentation on request, message us on WhatsApp at +91 7397976926.
Frequently asked questions
- A Company Wants 1,000 × 200 g Candles Delivered in 21 Days but I Normally Make Only 100 a Week — How Do I Calculate Whether I Can Realistically Accept the Order?
- How Do I Calculate My Maximum Candle Production Capacity Before Accepting a Large Corporate Order?
- I Need to Produce 1,000 Corporate Candles While Continuing Normal Website Sales — How Do I Calculate My True Available Production Capacity?
- Should I Reserve Specific Production Days Exclusively for a Large Candle Order Instead of Mixing It into Normal Production?
- A Corporate Client Wants Delivery in Two Weeks — Which Candle-Development Steps Should Never Be Skipped Even for an Urgent Order?
- How Do I Decide Whether to Accept a Bulk Candle Order Using Quantity, Deadline, Formulation Readiness, Production Capacity, Raw-Material Availability and Testing Time?
- A Wedding Client Wants 300 Candles in 10 Days — How Do I Calculate Whether My Current Moulds, Wax Capacity and Team Can Finish on Time?
Customer reviews: The six reviews at the top of this page are genuine, published Judge.me reviews left by CSI customers on the product pages named on each card — Black Glass Jar with Black Lid (150 gram) (Deliveries Starting 5th Dec), Ceramic Jar for Candle Making, Clear Glass Jar with Golden Lid (150 gram), Luxury Soy Wax Chunks for Jar / Container Candles. They are general product reviews, not assessments of the bulk-order advice on this page. Names, star ratings, dates and products are as recorded by Judge.me and wording is unedited. "Verified buyer" appears only on reviews Judge.me recorded as verified — Soumili Gope, Biny Abraham, Sakshi Jain, Kaushiki Satarkar, Jinal Patel. The reviews from Jinal are published but not recorded as verified, and carry no badge. Reviews below five stars are included as published, not filtered out.
Figures verified 7 October 2026, CSI live pricing: Clear Glass Jar with Golden Lid (150 gram) Pack of 10 ₹944.00, Pack of 20 ₹1,888.00 (₹94.40 a jar); Luxury Soy Wax Chunks 500 g ₹299.00, 1 kg ₹599.00, 5 kg ₹2,995.00, 10 kg ₹5,999.00; Japanese Cherry Blossom Fragrance Oil 15 g ₹104.00 (₹6.93/g), 50 g ₹270.00 (₹5.40/g), 100 g ₹500.00 (₹5.00/g), 500 g ₹2,500.00 (₹5.00/g), 1 kg ₹4,842.00 (₹4.84/g); Eco Candle Wicks Thin (C1) 20 ₹118.00, 50 ₹295.00, 100 ₹590.00, 500 ₹2,950.00, 1,000 ₹5,900.00 (₹5.90 a wick), 10-pack out of stock. Per unit = price ÷ grams or units, two decimals. Stock depth, batch continuity and dispatch dates for bulk quantities are not published: confirm on WhatsApp.
Non-price figures: the title gives no figures. The 1,500 × 150 g order, 8% load (on total weight: 12 g oil + 138 g wax), 100 candles a day demonstrated, 15 extras, 5% rejects, 2% breakage, 2% late defects, 1% heel, 2 set-up and 3 tail days, the one-remake-day and one-lost-day allowances, the stress-test delays and the 6-day week with day 1 a Monday are labelled worked examples; the 10–15% band and the 72-hour set are judgements. Wax and oil ceilings are as the pages state (Chunks up to 13%; Japanese Cherry Blossom 6–13% for candles): formulation limits, not regulatory ones; the jar page's "Safe for hot pour up to 85°C" is a pour limit. Costs are materials only and exclude labels, cartons, labour, freight, GST and marketing. Diwali 8 November 2026 is a calendar fact; the November–February wedding season is a commonly cited pattern.