Plastics Extrusion - Pipe, Film & Profile worked example

Extrusion Cost Per Pound at 99% yield or chargeable factor: a worked example

This scenario runs the extrusion cost per pound calculation on the strong side: 99% yield or chargeable factor, with every other input held at its documented default. Use it when quoting pipe, film, sheet, or profile jobs and comparing resin, labor, energy, and setup assumptions.

The inputs for this scenario

  • Finished production weight: 10,000 lb (unchanged)
  • Conversion cost rate: 0.38 $/lb (unchanged)
  • Yield or chargeable factor: 99 % (raised for this scenario; the documented default is 96)
  • Setup and changeover cost: 650 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Extrusion Cost Per Pound = finished production weight × conversion cost × yield or chargeable factor + setup and changeover cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4,412 $ for total extrusion cost, the number this scenario is built around.
  • At this operating point the engine returns 0.44 $ / lb for extrusion cost per pound.
  • At this operating point the engine returns 3,762 $ for variable conversion cost.
  • At this operating point the engine returns 650 $ for setup and changeover cost.

How this compares with the baseline

  • Against the tool's baseline example, where yield or chargeable factor sits at 96% and the headline result is 4,298 $, this scenario comes in 2.65% above the baseline at 4,412 $.
  • Use it to quote a run, set standard conversion rates, or compare the economics of long versus short jobs. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total extrusion cost: 4,412 $ (headline result)
  • Extrusion cost per pound: 0.44 $ / lb
  • Variable conversion cost: 3,762 $
  • Setup and changeover cost: 650 $

Run it with your numbers

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

Last reviewed 2026-05-12.