Plastics Extrusion - Pipe, Film & Profile worked example
Resin Drying Load at 99% dryer uptime: a worked example
Push dryer uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when checking whether dryers, hoppers, or material handling can support the extrusion schedule.
The inputs for this scenario
- Dry resin per dryer batch: 1,200 lb / batch (unchanged)
- Available dryer batches: 4 batches (unchanged)
- Dryer uptime: 99 % (raised for this scenario; the documented default is 92)
- Usable dry resin yield: 98 % (unchanged)
Working through the calculation
- Applying the documented formula (Gross capacity = dry resin per batch × available dryer batches) to the inputs above produces each figure below.
- At this operating point the engine returns 4,657 lb for usable dried resin capacity, the number this scenario is built around.
- At this operating point the engine returns 4,800 lb for gross dryer output.
- At this operating point the engine returns 48 lb for dryer uptime loss.
- At this operating point the engine returns 95.04 lb for dry resin yield loss.
How this compares with the baseline
- Against the tool's baseline example, where dryer uptime sits at 92% and the headline result is 4,328 lb, this scenario comes in 7.61% above the baseline at 4,657 lb.
- It computes usable dried resin capacity by multiplying batch size and batch count, then derating for dryer uptime and usable yield. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.
Results at a glance
- Usable dried resin capacity: 4,657 lb (headline result)
- Gross dryer output: 4,800 lb
- Dryer uptime loss: 48 lb
- Dry resin yield loss: 95.04 lb
Run it with your numbers
- Every input above is editable in the live Resin Drying Load calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.