Gaskets, Seals, O-Rings & Elastomer Components worked example

Extrusion Splice Loss at 2.88% target splice loss rate: a worked example

Push target splice loss rate up to 2.88% and the picture changes. This example computes every intermediate figure at that operating point. Use it when extrusion, splicing, and finishing teams need to understand how much material is lost to start-up scrap, splice defects, cutback, cure variation, or bad joints.

The inputs for this scenario

  • Rejected or lost extrusion length: 145 ft (unchanged)
  • Total extrusion length produced: 4,200 ft (unchanged)
  • Target splice loss rate: 2.88 % (raised for this scenario; the documented default is 2.5)

Working through the calculation

  • Applying the documented formula (Extrusion splice loss rate = rejected or lost extrusion length ÷ total extrusion length produced × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.45 % for extrusion splice loss rate, the number this scenario is built around.
  • At this operating point the engine returns -0.57 points for splice loss gap to target.
  • At this operating point the engine returns 145 count for rejected or lost extrusion length.
  • At this operating point the engine returns 4,200 count for total extrusion length produced.

How this compares with the baseline

  • Against the tool's baseline example, where target splice loss rate sits at 2.5% and the headline result is 3.45 %, this scenario lands almost exactly on the baseline at 3.45 %.
  • It divides rejected or lost extrusion length by total length produced and reports the loss percentage plus the point gap to your target rate. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Extrusion splice loss rate: 3.45 % (headline result)
  • Splice loss gap to target: -0.57 points
  • Rejected or lost extrusion length: 145 count
  • Total extrusion length produced: 4,200 count

Run it with your numbers

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

Last reviewed 2026-05-12.