Aluminum Extrusion & Profile Manufacturing worked example

Extrusion Saw Cut Loss Calculator at 2.88% target saw cut loss rate: a worked example

What does the result look like when target saw cut loss rate reaches 2.88%? The full calculation is worked below with real intermediate numbers. a cut-to-length planner needs to understand how saw kerf and trim affect extrusion order yield

The inputs for this scenario

  • Saw kerf and trim loss length: 185 ft (unchanged)
  • Total extruded length processed: 6,200 ft (unchanged)
  • Target saw cut loss rate: 2.88 % (raised for this scenario; the documented default is 2.5)

Working through the calculation

  • Applying the documented formula (Actual saw cut loss = saw kerf and trim loss length ÷ total extruded length processed × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 2.98 % cut loss for actual saw cut loss, the number this scenario is built around.
  • At this operating point the engine returns -0.1 points for cut-loss gap to target.
  • At this operating point the engine returns 185 ft for saw kerf and trim loss length.
  • At this operating point the engine returns 6,200 ft for total extruded length processed.

How this compares with the baseline

  • Against the tool's baseline example, where target saw cut loss rate sits at 2.5% and the headline result is 2.98 % cut loss, this scenario lands almost exactly on the baseline at 2.98 % cut loss.
  • A figure at this level is achievable when target saw cut loss rate is genuinely sustained, not just peaked for a shift. It only counts length lost at the saw — it does not capture press recovery, tongue-and-butt scrap, or quench-and-handling losses, so it is not a full metal-recovery figure.

Results at a glance

  • Actual saw cut loss: 2.98 % cut loss (headline result)
  • Cut-loss gap to target: -0.1 points
  • Saw kerf and trim loss length: 185 ft
  • Total extruded length processed: 6,200 ft

Run it with your numbers

  • Every input above is editable in the live Extrusion Saw Cut Loss Calculator calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.