Grain Milling, Dry Bulk Food & Feed Handling worked example

Energy Per Ton with measured process electrical load of 93 kW: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop measured process electrical load to 93 kW, then walk the calculation through step by step. Estimate energy cost per ton for milling, conveying, grinding, pelleting, mixing, or bagging using connected load, runtime, energy rate, and processed tons.

The inputs for this scenario

  • Measured process electrical load: 93 kW (the input this scenario stresses; the baseline uses 185)
  • Energy measurement runtime: 8 hr (held at the documented default)
  • Blended electricity rate: 0.11 $ / kWh (held at the documented default)
  • Dry bulk tons processed: 120 tons (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Energy cost = measured process load × energy measurement runtime × blended electricity rate.
  • Total process energy cost works out to 81.84 $ / ton at these inputs, and this is the headline figure for the scenario.
  • Process energy used works out to 744 kWh at these inputs.
  • Energy cost per ton works out to 0.68 $ / piece at these inputs.
  • Hourly process energy cost works out to 10.23 $ / hr at these inputs.

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 49.73% below the baseline at 81.84 $ / ton.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to measured process electrical load, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It uses an average load over the runtime; it won't capture peak-demand charges, power factor penalties, or startup surges that inflate the real bill.

Results at a glance

  • Total process energy cost: 81.84 $ / ton (headline result)
  • Process energy used: 744 kWh
  • Energy cost per ton: 0.68 $ / piece
  • Hourly process energy cost: 10.23 $ / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Energy Per Ton calculator, set measured process electrical load to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.