Plastics Extrusion - Pipe, Film & Profile worked example

Extrusion Cost Per Pound at 69% yield or chargeable factor: a worked example

This worked example runs the extrusion cost per pound numbers for a tougher week than the baseline: 69% yield or chargeable factor instead of the typical 96%. Build a run cost per pound from finished pounds, conversion cost per pound, yield factor, and fixed setup or changeover cost.

The inputs for this scenario

  • Finished production weight: 10,000 lb (held at the documented default)
  • Conversion cost rate: 0.38 $/lb (held at the documented default)
  • Yield or chargeable factor: 69 % (the input this scenario stresses; the baseline uses 96)
  • Setup and changeover cost: 650 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Extrusion Cost Per Pound = finished production weight × conversion cost × yield or chargeable factor + setup and changeover cost.
  • Total extrusion cost works out to 3,272 $ at these inputs, and this is the headline figure for the scenario.
  • Extrusion cost per pound works out to 0.33 $ / lb at these inputs.
  • Variable conversion cost works out to 2,622 $ at these inputs.
  • Setup and changeover cost works out to 650 $ at these inputs.

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 23.87% below the baseline at 3,272 $.
  • Use it to quote a run, set standard conversion rates, or compare the economics of long versus short jobs. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total extrusion cost: 3,272 $ (headline result)
  • Extrusion cost per pound: 0.33 $ / lb
  • Variable conversion cost: 2,622 $
  • Setup and changeover cost: 650 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Extrusion Cost Per Pound calculator, set yield or chargeable factor to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.