Glass Container & Bottle Manufacturing worked example

Energy per Ton with equivalent furnace energy load of 1,900 kW: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop equivalent furnace energy load to 1,900 kW, then walk the calculation through step by step. Estimate furnace and hot-end energy cost per ton of glass pulled using equivalent energy load, runtime, blended energy rate, and tons processed.

The inputs for this scenario

  • Equivalent furnace energy load: 1,900 kW (the input this scenario stresses; the baseline uses 3,850)
  • Energy measurement runtime: 24 hr (held at the documented default)
  • Blended energy rate: 0.09 $ / kWh (held at the documented default)
  • Glass tons processed: 460 tons (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total furnace energy cost = equivalent furnace energy load × energy measurement runtime × blended energy rate.
  • Total furnace energy cost works out to 3,876 $ / ton at these inputs, and this is the headline figure for the scenario.
  • Measured furnace energy use works out to 45,600 kWh at these inputs.
  • Energy cost per ton works out to 8.43 $ / piece at these inputs.
  • Hourly furnace energy cost works out to 162 $ / hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where equivalent furnace energy load sits at 3,850 kW and the headline result is 7,854 $ / ton, this scenario comes in 50.65% below the baseline at 3,876 $ / ton.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to equivalent furnace energy load, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. A single equivalent load and blended rate smooth over fuel mix, electric boost, and forehearth energy; for a granular bill you would model each energy stream separately.

Results at a glance

  • Total furnace energy cost: 3,876 $ / ton (headline result)
  • Measured furnace energy use: 45,600 kWh
  • Energy cost per ton: 8.43 $ / piece
  • Hourly furnace energy cost: 162 $ / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Energy per Ton calculator, set equivalent furnace energy load to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.