Paint, Resin & Polymer Compounding worked example

Resin Yield Loss at 2.16% target yield loss rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop target yield loss rate to 2.16%, then walk the calculation through step by step. Calculate resin batch yield loss as a percentage of theoretical output and compare it against your target loss rate.

The inputs for this scenario

  • Resin lost or off-spec: 30 gal (held at the documented default)
  • Theoretical batch output: 1,000 gal (held at the documented default)
  • Target yield loss rate: 2.16 % (the input this scenario stresses; the baseline uses 3)

Working through the calculation

  • The calculation starts from the formula this tool documents: Resin yield loss rate = resin lost or off-spec / theoretical batch output * 100.
  • Resin yield loss rate works out to 3 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target loss rate works out to -0.84 points at these inputs.
  • Resin lost or off-spec works out to 30 gal at these inputs.
  • Theoretical batch output works out to 1,000 gal at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target yield loss rate sits at 3% and the headline result is 3 %, this scenario lands almost exactly on the baseline at 3 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to target yield loss rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It measures loss as a single percentage and does not distinguish recoverable losses (reworkable off-spec) from unrecoverable ones (heel, drained solvent), so two lines with the same rate can have very different cost impact.

Results at a glance

  • Resin yield loss rate: 3 % (headline result)
  • Gap to target loss rate: -0.84 points
  • Resin lost or off-spec: 30 gal
  • Theoretical batch output: 1,000 gal

Run it with your numbers

  • To rerun this with your own numbers, open the live Resin Yield Loss calculator, set target yield loss rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.