I Need to Pour 100 Candles From One Large Wax Batch — How Do I Keep Temperature and Fragrance Distribution Consistent From Candle Number One to Candle Number 100?

Get the quantities right before anything else

Start with the arithmetic, because it decides your equipment plan. One hundred candles of 200 g is 20 kg of scented wax. At 8% fragrance load, measured as a percentage of total candle weight, that splits into 18.4 kg wax plus 1.6 kg oil. So far, so simple.

Real production loses wax: in the pitcher, on the melter walls, in spills, in rejected candles and in samples. A 5% planning allowance is a sensible starting point. Twenty kilograms after 5% wastage fills 95 candles, not 100. To finish with 100 good candles, divide the 20 kg by 0.95, which gives about 21.05 kg. Round up to 21.1 kg of scented wax: roughly 19.4 kg of wax and 1.69 kg of oil at 8%.

If you buy Luxury Soy Wax CSI 464 for this, two 10 kg packs at ₹5,074.00 each come to ₹10,148.00 and cover the 19.4 kg with a little spare. CSI 464 costs the same per kilogram at every pack size, so there is no saving from buying differently, only convenience.

One batch or two half-batches

The question says one large batch, and it is worth testing that assumption. The 20 kg Electric Wax Melter at ₹25,960.00 has a stated capacity of 20 kg. Your 21.1 kg does not fit in a single melt. You have three honest options.

Two half-batches means the same recipe made twice, not a different recipe. Both are weighed, heated, scented, stirred and poured to the same sheet, and both get sample candles. The gain is practical: a batch that sits well below the melter's brim can be stirred through its whole depth, and 50 candles pour in a shorter session in which the wax has less time to drift.

Making a matched top-up

If you choose the full melt plus a top-up, the top-up is a batch in its own right and must carry the same fragrance load. A 1.1 kg top-up at 8% is 1,012 g of wax and 88 g of oil. Weigh both, use the same wax pack and the same oil bottle as the main batch, and scent it at the same temperature. Pour it last, into candles numbered separately, so any difference can be traced.

Already own a 10 kg melter?

Then the 20 kg melter is not required for this order at all. Four quarter-batches of about 5.3 kg each, 21.1 kg divided by four, fit comfortably in the 10 kg Electric Wax Melter with room to stir. Each quarter fills 25 candles, which lines up exactly with the block plan below. You melt more often, but each batch is small enough to mix quickly and pour before it drifts, and the time lost to extra melts is often recovered in fewer rejects.

Pour in four blocks of 25

Whether you pour 100 from one melt or 50 from each of two, break the run into blocks. Each block boundary is a point at which you stop, check and correct before carrying on. Twenty-five is a suggested block size that divides 100 cleanly; validate it against your own pace and adjust if drift appears inside a block.

Set up the line so the plan survives the day

A block plan fails when the people are too busy to stop at the boundary. Decide in advance who pauses the line, and make pausing normal rather than a sign that something has gone wrong.

Stage everything before the first draw

All 100 jars wicked and placed, all labels or base numbers written, the scale tared and the thermometer at hand. Staging is what makes the block checks quick. A team that is still wicking jars at candle 60 will skip the checkpoint at 75.

One person for the melter, one for pouring

The melter owner stirs, draws and reads temperatures. The pourer fills jars and calls out candle numbers. At each boundary they swap roles for the checks: the pourer weighs, the melter owner re-reads the batch. Nobody has to remember to do both.

Safety at volume

A 20 kg melter at working temperature holds a lot of heat. Keep a clear path between the melter and the pouring table, wear heat-resistant gloves when drawing and returning wax, and check that the socket and wiring are rated for the melter's electrical load before a long session, especially if other equipment shares the circuit.

Use the four samples properly

The four block samples, numbers 25, 50, 75 and 100, are your evidence that the run was consistent. Cure them together with the rest of the batch, then light them together in one room. If they match each other and your approved test candle, the run is approved. If one block differs, your control sheet tells you exactly which checkpoint to look at and what was recorded there. Keep the control sheet with the batch record, because the next order for the same candle will start from it.

Where this page fits

CSI already has guides that cover parts of this question. This page takes the production-floor angle; these go deeper on the rest:

Three things to buy for this job

Frequently asked questions