How do you calculate extruder energy cost?

Multiply metered energy use by the electricity rate and the allocation factor, then add the fixed demand or support cost. With 1800 kWh at $0.11/kWh, 100% allocation and a $40 fixed charge, the total is $238.

Why is the cost per kWh higher than my utility rate?

Because the fixed demand or support cost is spread across the metered kWh. Here $238 over 1800 kWh works out to $0.1322/kWh even though the utility rate is only $0.11/kWh.

What does the allocation factor do?

It lets you charge only part of the energy to a specific job or product. At 100% the full 1800 kWh is allocated, giving $198 of variable energy cost; drop it to 50% and only half the metered energy is charged.

How much energy does an extrusion line use?

A typical single-screw line draws roughly 0.10-0.20 kWh per pound of throughput; higher for thin gauge film and lower for thick-wall pipe. Meter your own line rather than assume, because screw design and melt temperature dominate.

What is a good specific energy consumption for extrusion?

Well-run lines with efficient screws and good barrel insulation often land near 0.10-0.13 kWh/lb of melt; anything above 0.20 kWh/lb usually signals worn screws, excess melt temperature, or poor insulation.

How do I lower extruder energy cost?

Insulate the barrel, right-size the drive, run at the lowest safe melt temperature, and shift startup or purge-heavy runs to off-peak hours to cut both the rate and the fixed demand charge.

Plastics Extrusion - Pipe, Film & Profile calculator

Extruder Energy Cost Calculator

Extruder energy cost tells a plastics processor what a given production run actually costs in electricity, combining metered kWh at the barrel heaters, screw drive, and downstream cooling with the plant's utility rate. Extrusion is one of the most energy-intensive conversion processes in plastics, so process engineers and cost estimators use this number to load energy into a quote and to justify barrel insulation, drive upgrades, or off-peak scheduling. Because a single 90 mm pipe or blown-film line can pull 150-300 kW continuously, small rate or efficiency changes move real dollars. This calculator adds a fixed demand or support cost on top of metered consumption so the total reflects the full cost of keeping the line energized.

What this calculator does

Estimate extrusion energy cost from metered kilowatt-hours, utility rate, load capture factor, and fixed demand or support cost.
Use it when quoting or reviewing the energy cost of an extruder, downstream line, dryer, or chiller load.
It computes total run energy cost as metered kWh times electricity rate times an allocation factor, plus a fixed demand or support charge, and returns the effective cost per kWh.

Formula used

Extruder Energy Cost = metered energy use × electricity rate × run allocation factor + fixed demand or support cost
Per-unit cost = total cost ÷ metered energy use

Inputs explained

Metered extruder energy use:
Utility electricity rate:
Line run-time allocation factor:
Fixed demand and support charge:

How to use the result

Use it when you need the electricity portion of a run's conversion cost for quoting, cost-down projects, or comparing lines and shifts.
It assumes your metered kWh already captures the full line draw; if you sub-meter only the drive and miss heaters or chillers, the total understates true energy cost.

Current U.S. benchmarks

As of Apr 2026, industrial electricity averages 8.7 cents per kWh across the U.S. (EIA), up 5.5% from a year earlier. State averages range widely, so plants should confirm against their own tariff.
The producer price index for steel mill products stands at 348.53 (BLS, May 2026), up 6.7% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for aluminum mill shapes stands at 404.859 (BLS, May 2026), up 36.8% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for plastic resins and materials stands at 319.371 (BLS, May 2026), up 19.5% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The U.S. has 3,569 primary metal manufacturing establishments employing about 354,911 workers (Census County Business Patterns, 2023).

Common questions

How do you calculate extruder energy cost? Multiply metered energy use by the electricity rate and the allocation factor, then add the fixed demand or support cost. With 1800 kWh at $0.11/kWh, 100% allocation and a $40 fixed charge, the total is $238.
Why is the cost per kWh higher than my utility rate? Because the fixed demand or support cost is spread across the metered kWh. Here $238 over 1800 kWh works out to $0.1322/kWh even though the utility rate is only $0.11/kWh.
What does the allocation factor do? It lets you charge only part of the energy to a specific job or product. At 100% the full 1800 kWh is allocated, giving $198 of variable energy cost; drop it to 50% and only half the metered energy is charged.
How much energy does an extrusion line use? A typical single-screw line draws roughly 0.10-0.20 kWh per pound of throughput; higher for thin gauge film and lower for thick-wall pipe. Meter your own line rather than assume, because screw design and melt temperature dominate.
What is a good specific energy consumption for extrusion? Well-run lines with efficient screws and good barrel insulation often land near 0.10-0.13 kWh/lb of melt; anything above 0.20 kWh/lb usually signals worn screws, excess melt temperature, or poor insulation.

Last reviewed 2026-05-12.