Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Gasket Compression Loss with gasket use rate of 190 gaskets / hr: a worked example

What does the result look like when gasket use rate reaches 190 gaskets / hr? The full calculation is worked below with real intermediate numbers. Use it when a process or quality engineer is evaluating a gasket material change (for example moving from EPDM to PTFE-graphite) and needs to see the dollar impact of compression set or rework on the per-stack BOM.

The inputs for this scenario

  • Gasket use rate: 190 gaskets / hr (raised for this scenario; the documented default is 75)
  • Build runtime per stack: 4 hr (unchanged)
  • Loaded cost per gasket: 3.25 $ / gasket (unchanged)

Working through the calculation

  • Applying the documented formula (Gasket consumption per stack = gasket use rate × build runtime per stack) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,470 $ for gasket cost per stack, the number this scenario is built around.
  • At this operating point the engine returns 760 units for gasket consumption per stack.
  • At this operating point the engine returns 4 hr for build runtime per stack.
  • At this operating point the engine returns 3.25 $ / unit for loaded cost per gasket.

How this compares with the baseline

  • Against the tool's baseline example, where gasket use rate sits at 75 gaskets / hr and the headline result is 975 $, this scenario comes in 153% above the baseline at 2,470 $.
  • A figure at this level is achievable when gasket use rate is genuinely sustained, not just peaked for a shift. It assumes a steady gasket use rate across the whole build; in reality consumption spikes during cell stacking and may be near zero during fixturing, so the average can hide where loss concentrates.

Results at a glance

  • Gasket cost per stack: 2,470 $ (headline result)
  • Gasket consumption per stack: 760 units
  • Build runtime per stack: 4 hr
  • Loaded cost per gasket: 3.25 $ / unit

Run it with your numbers

  • Every input above is editable in the live Gasket Compression Loss calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.