Graphite, Anode & Battery Materials Processing worked example

Coating Solids Usage with dry coating solids feed rate of 45 kg / hr: a worked example

What does the result look like when dry coating solids feed rate reaches 45 kg / hr? The full calculation is worked below with real intermediate numbers. Use it when coating, procurement, or costing teams need to budget pitch, resin, carbon precursor, conductive carbon, or other coating solids for a coating campaign.

The inputs for this scenario

  • Dry coating solids feed rate: 45 kg / hr (raised for this scenario; the documented default is 18)
  • Coating campaign runtime: 10 hr (unchanged)
  • Coating solids cost: 12.5 $ / kg (unchanged)

Working through the calculation

  • Applying the documented formula (Coating solids consumed = dry coating solids feed rate × coating campaign runtime) to the inputs above produces each figure below.
  • At this operating point the engine returns 450 kg for coating solids consumed, the number this scenario is built around.
  • At this operating point the engine returns 5,625 $ for coating solids run cost.
  • At this operating point the engine returns 10 hr for coating campaign runtime.
  • At this operating point the engine returns 12.5 $ / unit for coating solids cost.

How this compares with the baseline

  • Against the tool's baseline example, where dry coating solids feed rate sits at 18 kg / hr and the headline result is 180 kg, this scenario comes in 150% above the baseline at 450 kg.
  • A figure at this level is achievable when dry coating solids feed rate is genuinely sustained, not just peaked for a shift. It assumes a constant feed rate and ignores carrier solvent, coating transfer efficiency and overspray, so true material drawn from inventory can exceed the deposited solids.

Results at a glance

  • Coating solids consumed: 450 kg (headline result)
  • Coating solids run cost: 5,625 $
  • Coating campaign runtime: 10 hr
  • Coating solids cost: 12.5 $ / unit

Run it with your numbers

  • Every input above is editable in the live Coating Solids Usage calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.