Heat Exchanger, Coil & Radiator Manufacturing worked example

Scrap Fin/Tube Cost at 92% recoverable cost capture factor: a worked example

This scenario runs the scrap fin/tube cost calculation on the strong side: 92% recoverable cost capture factor, with every other input held at its documented default. Use it when crushed fins, wrong fin pitch, damaged tubes, bend scrap, expansion defects, or leak rejects are driving material loss.

The inputs for this scenario

  • Scrapped fins or tubes: 100 units (unchanged)
  • Material cost per scrapped fin or tube: 45 $ / unit (unchanged)
  • Recoverable cost capture factor: 92 % (raised for this scenario; the documented default is 80)
  • Fixed scrap handling and disposal cost: 250 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Fin and tube scrap cost = scrapped units × material cost per unit × cost capture factor + fixed scrap handling cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,390 $ for fin and tube scrap cost, the number this scenario is built around.
  • At this operating point the engine returns 43.9 $ / piece for scrap cost per affected unit.
  • At this operating point the engine returns 4,140 $ for captured material loss.
  • At this operating point the engine returns 250 $ for fixed handling cost.

How this compares with the baseline

  • Against the tool's baseline example, where recoverable cost capture factor sits at 80% and the headline result is 3,850 $, this scenario comes in 14.03% above the baseline at 4,390 $.
  • Use it when quantifying a defect mode for a cost-reduction project, building scrap variance reports, or comparing the loss from competing tooling or material options. 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

  • Fin and tube scrap cost: 4,390 $ (headline result)
  • Scrap cost per affected unit: 43.9 $ / piece
  • Captured material loss: 4,140 $
  • Fixed handling cost: 250 $

Run it with your numbers

  • Every input above is editable in the live Scrap Fin/Tube Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.