Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Gasket Compression Loss with gasket use rate of 38 gaskets / hr: a worked example

This worked example runs the gasket compression loss numbers for a tougher week than the baseline: gasket use rate of 38 gaskets / hr instead of the typical 75 gaskets / hr. Estimate gasket replacement cost per stack from the gasket consumption rate (gaskets used per build hour, including reject and rework), the build runtime, and the loaded gasket cost.

The inputs for this scenario

  • Gasket use rate: 38 gaskets / hr (the input this scenario stresses; the baseline uses 75)
  • Build runtime per stack: 4 hr (held at the documented default)
  • Loaded cost per gasket: 3.25 $ / gasket (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gasket consumption per stack = gasket use rate × build runtime per stack.
  • Gasket cost per stack works out to 494 $ at these inputs, and this is the headline figure for the scenario.
  • Gasket consumption per stack works out to 152 units at these inputs.
  • Build runtime per stack works out to 4 hr at these inputs.
  • Loaded cost per gasket works out to 3.25 $ / unit at these inputs.

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 49.33% below the baseline at 494 $.
  • Use it when costing the seal consumable per stack, comparing gasket vendors or grades, or quantifying scrap from compression and handling damage. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Gasket cost per stack: 494 $ (headline result)
  • Gasket consumption per stack: 152 units
  • Build runtime per stack: 4 hr
  • Loaded cost per gasket: 3.25 $ / unit

Run it with your numbers

  • To rerun this with your own numbers, open the live Gasket Compression Loss calculator, set gasket use rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.