Plastics Extrusion - Pipe, Film & Profile worked example

Regrind Blend Rate at 12% target or max regrind rate: a worked example

This scenario runs the regrind blend rate calculation on the strong side: 12% target or max regrind rate, with every other input held at its documented default. Use it when setting regrind levels for pipe, film, sheet, or profile runs while staying inside quality or customer limits.

The inputs for this scenario

  • Regrind weight in blend: 400 lb (unchanged)
  • Total blend weight: 5,000 lb (unchanged)
  • Target or max regrind rate: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

  • Applying the documented formula (Regrind Blend Rate = regrind weight in blend รท total blend weight) to the inputs above produces each figure below.
  • At this operating point the engine returns 8 % for regrind blend rate, the number this scenario is built around.
  • At this operating point the engine returns 4 points for gap to regrind target.
  • At this operating point the engine returns 400 count for regrind weight.
  • At this operating point the engine returns 5,000 count for total blend weight.

How this compares with the baseline

  • Against the tool's baseline example, where target or max regrind rate sits at 10% and the headline result is 8 %, this scenario lands almost exactly on the baseline at 8 %.
  • Use it when setting or auditing a hopper recipe to capture scrap value without violating a spec regrind cap. 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

  • Regrind blend rate: 8 % (headline result)
  • Gap to regrind target: 4 points
  • Regrind weight: 400 count
  • Total blend weight: 5,000 count

Run it with your numbers

  • Every input above is editable in the live Regrind Blend Rate calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.