Grain Milling, Dry Bulk Food & Feed Handling worked example

Energy Per Ton with measured process electrical load of 460 kW: a worked example

This scenario runs the energy per ton calculation on the strong side: measured process electrical load of 460 kW, with every other input held at its documented default. Use it when operations or finance needs to compare energy intensity by mill line, product, grind size, pellet run, or conveying route.

The inputs for this scenario

  • Measured process electrical load: 460 kW (raised for this scenario; the documented default is 185)
  • Energy measurement runtime: 8 hr (unchanged)
  • Blended electricity rate: 0.11 $ / kWh (unchanged)
  • Dry bulk tons processed: 120 tons (unchanged)

Working through the calculation

  • Applying the documented formula (Energy cost = measured process load × energy measurement runtime × blended electricity rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 405 $ / ton for total process energy cost, the number this scenario is built around.
  • At this operating point the engine returns 3,680 kWh for process energy used.
  • At this operating point the engine returns 3.37 $ / piece for energy cost per ton.
  • At this operating point the engine returns 50.6 $ / hr for hourly process energy cost.

How this compares with the baseline

  • Against the tool's baseline example, where measured process electrical load sits at 185 kW and the headline result is 163 $ / ton, this scenario comes in 149% above the baseline at 405 $ / ton.
  • Use it to benchmark grinding or pelleting energy, evaluate efficiency projects, or build accurate per-ton cost standards for quoting. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total process energy cost: 405 $ / ton (headline result)
  • Process energy used: 3,680 kWh
  • Energy cost per ton: 3.37 $ / piece
  • Hourly process energy cost: 50.6 $ / hr

Run it with your numbers

  • Every input above is editable in the live Energy Per Ton calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.