Plastics Extrusion - Pipe, Film & Profile worked example

Finished Roll/Coil Capacity at 99% winder availability: a worked example

What does the result look like when winder availability reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when planning blown film rolls, cast film rolls, sheet coils, pipe coils, or profile coil capacity.

The inputs for this scenario

  • Finished rolls or coils per winding cycle: 2 rolls or coils / cycle (unchanged)
  • Available winding cycles in period: 180 cycles (unchanged)
  • Winder availability: 99 % (raised for this scenario; the documented default is 90)
  • Finished-goods yield after winding: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross capacity = finished rolls or coils per cycle × available winding cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 342 rolls or coils for good roll or coil capacity, the number this scenario is built around.
  • At this operating point the engine returns 360 rolls or coils for gross roll or coil capacity.
  • At this operating point the engine returns 3.6 rolls or coils for winder uptime loss.
  • At this operating point the engine returns 14.26 rolls or coils for finished goods yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where winder availability sits at 90% and the headline result is 311 rolls or coils, this scenario comes in 10% above the baseline at 342 rolls or coils.
  • A figure at this level is achievable when winder availability is genuinely sustained, not just peaked for a shift. It assumes uniform rolls per cycle and a constant yield; mixed roll widths, diameters or downgrades within the period will skew the good-capacity figure.

Results at a glance

  • Good roll or coil capacity: 342 rolls or coils (headline result)
  • Gross roll or coil capacity: 360 rolls or coils
  • Winder uptime loss: 3.6 rolls or coils
  • Finished goods yield loss: 14.26 rolls or coils

Run it with your numbers

  • Every input above is editable in the live Finished Roll/Coil Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.