Paint, Resin & Polymer Compounding worked example

Color Match Rework with gallons reworked of 250 gal: a worked example

This worked example runs the color match rework numbers for a tougher week than the baseline: gallons reworked of 250 gal instead of the typical 500 gal. Estimate the cost of retinting and reworking off-shade batches from gallons reworked, tint and labor cost per gallon, and fixed retest cost.

The inputs for this scenario

  • Gallons reworked: 250 gal (the input this scenario stresses; the baseline uses 500)
  • Tint and labor cost per gallon: 0.6 $ / gal (held at the documented default)
  • Fixed retint and retest cost: 120 $ (held at the documented default)
  • QC and overhead adder: 80 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total color match rework cost = gallons reworked * tint and labor cost per gallon + fixed retint and retest cost + QC and overhead adder.
  • Total color match rework cost works out to 350 $ at these inputs, and this is the headline figure for the scenario.
  • Rework cost per gallon works out to 1.4 $ / piece at these inputs.
  • Tint and labor cost works out to 150 $ at these inputs.
  • Fixed retint and QC cost works out to 200 $ at these inputs.

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 30% below the baseline at 350 $.
  • Use it every time a batch fails color and gets retinted, to quantify the cost of the miss and build a case for reducing repeat color rejects. 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

  • Total color match rework cost: 350 $ (headline result)
  • Rework cost per gallon: 1.4 $ / piece
  • Tint and labor cost: 150 $
  • Fixed retint and QC cost: 200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Color Match Rework calculator, set gallons reworked to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.