Plastics Extrusion - Pipe, Film & Profile worked example

Extruder Energy Cost at 72% line run-time allocation factor: a worked example

Suppose line run-time allocation factor falls to 72%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate extrusion energy cost from metered kilowatt-hours, utility rate, load capture factor, and fixed demand or support cost.

The inputs for this scenario

  • Metered extruder energy use: 1,800 kWh (held at the documented default)
  • Utility electricity rate: 0.11 $/kWh (held at the documented default)
  • Line run-time allocation factor: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed demand and support charge: 40 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Extruder Energy Cost = metered energy use × electricity rate × run allocation factor + fixed demand or support cost.
  • Extrusion energy cost works out to 183 $ at these inputs, and this is the headline figure for the scenario.
  • Energy cost per kWh entered works out to 0.1 $ / kWh at these inputs.
  • Allocated energy cost works out to 143 $ at these inputs.
  • Fixed energy cost works out to 40 $ at these inputs.

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 23.29% below the baseline at 183 $.
  • 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Extrusion energy cost: 183 $ (headline result)
  • Energy cost per kWh entered: 0.1 $ / kWh
  • Allocated energy cost: 143 $
  • Fixed energy cost: 40 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Extruder Energy Cost calculator, set line run-time allocation factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.