Plastics Extrusion - Pipe, Film & Profile worked example

Extruder Energy Cost at 110% line run-time allocation factor: a worked example

What does the result look like when line run-time allocation factor reaches 110%? The full calculation is worked below with real intermediate numbers. Use it when quoting or reviewing the energy cost of an extruder, downstream line, dryer, or chiller load.

The inputs for this scenario

  • Metered extruder energy use: 1,800 kWh (unchanged)
  • Utility electricity rate: 0.11 $/kWh (unchanged)
  • Line run-time allocation factor: 110 % (raised for this scenario; the documented default is 100)
  • Fixed demand and support charge: 40 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Extruder Energy Cost = metered energy use × electricity rate × run allocation factor + fixed demand or support cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 258 $ for extrusion energy cost, the number this scenario is built around.
  • At this operating point the engine returns 0.14 $ / kWh for energy cost per kwh entered.
  • At this operating point the engine returns 218 $ for allocated energy cost.
  • At this operating point the engine returns 40 $ for fixed energy cost.

How this compares with the baseline

  • Against the tool's baseline example, where line run-time allocation factor sits at 100% and the headline result is 238 $, this scenario comes in 8.32% above the baseline at 258 $.
  • A figure at this level is achievable when line run-time allocation factor is genuinely sustained, not just peaked for a shift. 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.

Results at a glance

  • Extrusion energy cost: 258 $ (headline result)
  • Energy cost per kWh entered: 0.14 $ / kWh
  • Allocated energy cost: 218 $
  • Fixed energy cost: 40 $

Run it with your numbers

  • Every input above is editable in the live Extruder Energy Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.