Foam, Insulation & Cushioning Products worked example

Foam Block Yield at 99% target block yield: a worked example

What does the result look like when target block yield reaches 99%? The full calculation is worked below with real intermediate numbers. Use it after peeling skin, trimming edges, splitting sheets, contour cutting, or rejecting voids so yield loss is visible before quoting or scheduling more blocks.

The inputs for this scenario

  • Accepted usable foam volume: 86 ft³ (unchanged)
  • Poured or purchased block volume: 100 ft³ (unchanged)
  • Target block yield: 99 % (raised for this scenario; the documented default is 88)

Working through the calculation

  • Applying the documented formula (Foam Block Yield rate = accepted usable foam volume ÷ poured or purchased block volume × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 86 % for foam block yield rate, the number this scenario is built around.
  • At this operating point the engine returns 13 points for foam block yield gap to target.
  • At this operating point the engine returns 86 ft³ for accepted usable foam volume.
  • At this operating point the engine returns 100 ft³ for poured or purchased block volume.

How this compares with the baseline

  • Against the tool's baseline example, where target block yield sits at 88% and the headline result is 86 %, this scenario lands almost exactly on the baseline at 86 %.
  • A figure at this level is achievable when target block yield is genuinely sustained, not just peaked for a shift. It is a volume yield only — it does not weight by foam grade or value, so trimming low-value skin counts the same as losing premium core.

Results at a glance

  • Foam Block Yield rate: 86 % (headline result)
  • Foam Block Yield gap to target: 13 points
  • Accepted usable foam volume: 86 ft³
  • Poured or purchased block volume: 100 ft³

Run it with your numbers

  • Every input above is editable in the live Foam Block Yield calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.