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

Extrusion Splice Loss at 1.8% target splice loss rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop target splice loss rate to 1.8%, then walk the calculation through step by step. Calculate extrusion splice loss for cord seals, bulb seals, edge seals, sponge profiles, and cut-to-length elastomer extrusions.

The inputs for this scenario

  • Rejected or lost extrusion length: 145 ft (held at the documented default)
  • Total extrusion length produced: 4,200 ft (held at the documented default)
  • Target splice 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: Extrusion splice loss rate = rejected or lost extrusion length ÷ total extrusion length produced × 100.
  • Extrusion splice loss rate works out to 3.45 % at these inputs, and this is the headline figure for the scenario.
  • Splice loss gap to target works out to -1.65 points at these inputs.
  • Rejected or lost extrusion length works out to 145 count at these inputs.
  • Total extrusion length produced works out to 4,200 count at these inputs.

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 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target splice loss rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It measures total lost length, not whether the loss came from splices, purge, or off-spec profile — break it down by cause before acting.

Results at a glance

  • Extrusion splice loss rate: 3.45 % (headline result)
  • Splice loss gap to target: -1.65 points
  • Rejected or lost extrusion length: 145 count
  • Total extrusion length produced: 4,200 count

Run it with your numbers

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

Last reviewed 2026-05-12.