Paint, Resin & Polymer Compounding worked example

Color Match Rework with gallons reworked of 1,300 gal: a worked example

Push gallons reworked up to 1,300 gal and the picture changes. This example computes every intermediate figure at that operating point. you need to price the cost of bringing an off-shade batch back to standard or justify investment in better color control

The inputs for this scenario

  • Gallons reworked: 1,300 gal (raised for this scenario; the documented default is 500)
  • Tint and labor cost per gallon: 0.6 $ / gal (unchanged)
  • Fixed retint and retest cost: 120 $ (unchanged)
  • QC and overhead adder: 80 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total color match rework cost = gallons reworked * tint and labor cost per gallon + fixed retint and retest cost + QC and overhead adder) to the inputs above produces each figure below.
  • At this operating point the engine returns 980 $ for total color match rework cost, the number this scenario is built around.
  • At this operating point the engine returns 0.75 $ / piece for rework cost per gallon.
  • At this operating point the engine returns 780 $ for tint and labor cost.
  • At this operating point the engine returns 200 $ for fixed retint and qc cost.

How this compares with the baseline

  • Against the tool's baseline example, where gallons reworked sits at 500 gal and the headline result is 500 $, this scenario comes in 96% above the baseline at 980 $.
  • It sums variable tint and labor cost across the reworked gallons plus fixed retint, retest, QC, and overhead charges to give total rework cost and cost per gallon. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total color match rework cost: 980 $ (headline result)
  • Rework cost per gallon: 0.75 $ / piece
  • Tint and labor cost: 780 $
  • Fixed retint and QC cost: 200 $

Run it with your numbers

  • Every input above is editable in the live Color Match Rework calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.