Mattress, Bedding & Foam Product Assembly worked example

Roll-Pack Film Cost at 66% film utilization rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop film utilization rate to 66%, then walk the calculation through step by step. Calculate the total cost of compression roll-pack film (PE shrink wrap) for a bed-in-a-box production run based on film usage per mattress and material cost.

The inputs for this scenario

  • Mattresses to pack: 200 mattresses (held at the documented default)
  • Film cost per mattress: 2.5 $ / mattress (held at the documented default)
  • Film utilization rate: 66 % (the input this scenario stresses; the baseline uses 92)
  • Fixed film handling cost: 40 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross film cost = mattresses × film cost per mattress ÷ (utilization rate ÷ 100).
  • Weighted cost works out to 370 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 1.85 $ / piece at these inputs.
  • Captured value works out to 330 $ at these inputs.
  • Fixed adjustment works out to 40 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where film utilization rate sits at 92% and the headline result is 500 $, this scenario comes in 26% below the baseline at 370 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to film utilization rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It models film only — it ignores corrugate cartons, labels, and the energy cost of the compression press, so it is not a full packaging cost-of-goods figure.

Results at a glance

  • Weighted cost: 370 $ (headline result)
  • Per piece value: 1.85 $ / piece
  • Captured value: 330 $
  • Fixed adjustment: 40 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Roll-Pack Film Cost calculator, set film utilization rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.