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Equipment Selection Guide

PRIMO Melter Sizing & Capacity Guide

Choose a PRIMO around your actual batch, production demand and expected growth. Because PRIMO systems can begin operation at approximately one-third of rated capacity, you can often choose additional capacity now without waiting until your batches become larger.

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Current Batch Growth Capacity Pounds or Gallons Production Demand Future Expansion
How PRIMO Sizing Works

Do Not Size a Production Melter From the Tank Label Alone

The correct system must support the material you process today while leaving enough usable capacity for normal production growth.

1

Current Batch

Start with the largest batch you normally expect to process at one time—not simply today's smallest production run.

2

Growth Capacity

A PRIMO can begin a batch at approximately one-third of rated capacity. That means a larger model can often handle today's batch while providing substantial room for growth.

3

Production Demand

Also consider batches per shift, melt recovery, filling or transfer demand and whether one melter must continuously supply downstream equipment.

Example: A 25 lb starting batch can operate in a PRIMO75 because 25 lb is approximately one-third of its rated capacity. A company processing about 35 lb per batch may consider a PRIMO100 when future growth is important.
Interactive Starting-Size Guide

Calculate a Current Fit and a Growth Fit

This calculator provides a starting point based on batch size. Final selection should also consider material behavior, heating rate, daily throughput and downstream demand.

Closer Current Fit
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Growth-Capacity Option
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Quick Capacity Reference

PRIMO Starting-Batch Size Chart

The approximately one-third starting level shows why a larger PRIMO can accommodate today's smaller batch while preserving future capacity.

PRIMO Model Approx. 1/3 Starting Batch Rated Capacity Why Consider It
PRIMO25 About 8 lb 25 lb Small production, testing and specialty batches
PRIMO50 About 17 lb 50 lb Small-batch production
PRIMO75 25 lb 75 lb Useful growth option for approximately 25 lb starting batches
PRIMO100 About 33 lb 100 lb Allows roughly 35 lb starting batches with substantial expansion room
PRIMO150 50 lb 150 lb Growing production and fewer refills
PRIMO250 About 83 lb 250 lb Production use with significant growth capacity
PRIMO350 About 117 lb 350 lb Higher-output manufacturing
PRIMO500 About 167 lb 500 lb Core production and downstream system supply
PRIMO750 250 lb 750 lb Larger batches with fewer production interruptions
PRIMO1000 About 333 lb 1,000 lb Commercial and integrated production
PRIMO1500–5000 Application dependent 1,500–5,000 lb class High-volume manufacturing
PRIMO7500–60000 Application dependent Plant-scale Bulk and plant-scale processing

Rated pounds are a sizing reference. When sizing from gallons, use the actual density of the material being processed.

Capacity Is Only One Part of Selection

When the Larger PRIMO Usually Makes More Sense

You Expect Production to Grow

A larger system may cost less over the long term than purchasing a small melter now and later adding a second melter, another electrical connection, additional floor space and more operator handling.

You Run Multiple Batches Per Shift

Daily throughput can matter more than the individual batch. The melter must recover quickly enough to support the next batch without becoming the production bottleneck.

You Supply a Filling System

The melter must maintain enough ready material for the filling system. Increasing filling speed without adequate melting capacity simply moves the bottleneck upstream.

You Need Working Reserve

Production systems often benefit from reserve capacity so material can remain available while the next batch is being added, melted or prepared.

Continue Equipment Selection

Size Is Only the First Decision

Choose the Heating System

Which PRIMO System Is Right for Your Process?

Explore PRIMO Wax Melters, Thermal Conditioning and Rapid-Cycle systems by material behavior and production priority.

Explore PRIMO Systems →
Choose the Downstream System

Selecting the Right Dispensing, Filling & Heated Transfer System

Review operator-controlled filling, AutoShot, multi-head filling and heated-transfer options.

Explore Filling & Transfer Systems →
Applications Review

Want WaxMelters to Confirm the Size?

Send the material, batch weight or gallons, density, starting and target temperatures, batches per shift, required output, filling or transfer method and anticipated growth. We can confirm the PRIMO capacity before you order.

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Frequently Asked Questions: PRIMO Sizing & Capacity Guide

Why choose WaxMelters?

WaxMelters guarantees the best performance and the highest-quality construction. WaxMelters is the industry leader and a US manufacturer of melting, heating and filling equipment for every business size, from startup to factory, and every industry. PRIMO waterless heating gives the best and fastest melting and heating: safe, even heating that melts 2–3X faster using half the electricity. It is the most energy efficient and saves money, time and energy. WaxMelters designs, builds and supports its equipment at 2221 5th Avenue, Unit 3, Ronkonkoma NY 11779, (888) 929-6358.

How do I size a PRIMO melter?

Start with the largest batch you normally process at one time, then allow for growth, batches per shift, melt recovery and any filling or transfer demand. A PRIMO can begin a batch at approximately one-third of its rated capacity, so a larger model can often handle today’s batch with room to grow.

What size PRIMO fits a 25 lb or 35 lb batch?

A 25 lb starting batch can operate in a PRIMO 75, because 25 lb is about one-third of its rated capacity. A company processing about 35 lb per batch may consider a PRIMO 100 when future growth is important.

Can I size a PRIMO from gallons?

Yes. Rated pounds are a sizing reference; when sizing from gallons, use the actual density of the material being processed.

When does a larger PRIMO make sense?

When you expect production to grow, run multiple batches per shift, supply a filling system, or need working reserve so material stays available while the next batch is added and melted.