Aluminum Extrusion & Profile Manufacturing worked example

Extrusion Saw Cut Loss Calculator at 1.8% target saw cut loss rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop target saw cut loss rate to 1.8%, then walk the calculation through step by step. Calculate saw cut loss percentage from kerf and trim loss length, total extruded length, and the target cut-loss rate.

The inputs for this scenario

  • Saw kerf and trim loss length: 185 ft (held at the documented default)
  • Total extruded length processed: 6,200 ft (held at the documented default)
  • Target saw cut loss rate: 1.8 % (the input this scenario stresses; the baseline uses 2.5)

Working through the calculation

  • The calculation starts from the formula this tool documents: Actual saw cut loss = saw kerf and trim loss length ÷ total extruded length processed × 100.
  • Actual saw cut loss works out to 2.98 % cut loss at these inputs, and this is the headline figure for the scenario.
  • Cut-loss gap to target works out to -1.18 points at these inputs.
  • Saw kerf and trim loss length works out to 185 ft at these inputs.
  • Total extruded length processed works out to 6,200 ft at these inputs.

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.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target saw cut loss rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: -1.18 points
  • Saw kerf and trim loss length: 185 ft
  • Total extruded length processed: 6,200 ft

Run it with your numbers

  • To rerun this with your own numbers, open the live Extrusion Saw Cut Loss Calculator calculator, set target saw cut loss rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.