Building Materials Manufacturing worked example

Glass Remelt Savings at 110% savings assigned to this furnace, line, or product: a worked example

What does the result look like when savings assigned to this furnace, line, or product reaches 110%? The full calculation is worked below with real intermediate numbers. a glass plant needs to quantify savings from remelting cullet or internal scrap

The inputs for this scenario

  • Cullet or scrap glass returned to remelt: 1,200 tons (unchanged)
  • Avoided virgin batch or disposal cost per ton: 35 $ / ton (unchanged)
  • Savings assigned to this furnace, line, or product: 110 % (raised for this scenario; the documented default is 100)
  • Fixed sorting, crushing, or handling cost: 650 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Allocated glass remelt savings = cullet or scrap glass returned to remelt × avoided virgin batch or disposal cost per ton × allocation share) to the inputs above produces each figure below.
  • At this operating point the engine returns 46,850 $ remelt savings for glass remelt savings, the number this scenario is built around.
  • At this operating point the engine returns 39.04 $ / piece for avoided virgin batch or disposal cost per ton.
  • At this operating point the engine returns 46,200 $ for allocated glass remelt savings.
  • At this operating point the engine returns 650 $ for fixed sorting, crushing, or handling cost.

How this compares with the baseline

  • Against the tool's baseline example, where savings assigned to this furnace, line, or product sits at 100% and the headline result is 42,650 $ remelt savings, this scenario comes in 9.85% above the baseline at 46,850 $ remelt savings.
  • A figure at this level is achievable when savings assigned to this furnace, line, or product is genuinely sustained, not just peaked for a shift. It assumes a constant avoided cost per ton; in reality, contamination and color mixing degrade cullet value, and beyond ~60-80% cullet ratio furnace chemistry and pull rate impose hard limits.

Results at a glance

  • Glass Remelt Savings: 46,850 $ remelt savings (headline result)
  • Avoided virgin batch or disposal cost per ton: 39.04 $ / piece
  • Allocated glass remelt savings: 46,200 $
  • Fixed sorting, crushing, or handling cost: 650 $

Run it with your numbers

  • Every input above is editable in the live Glass Remelt Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.