Plastics Extrusion - Pipe, Film & Profile worked example

Resin Drying Load at 66% dryer uptime: a worked example

Suppose dryer uptime falls to 66%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate usable dried resin capacity from dryer batch size, available batches, uptime, and dry resin yield.

The inputs for this scenario

  • Dry resin per dryer batch: 1,200 lb / batch (held at the documented default)
  • Available dryer batches: 4 batches (held at the documented default)
  • Dryer uptime: 66 % (the input this scenario stresses; the baseline uses 92)
  • Usable dry resin yield: 98 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross capacity = dry resin per batch × available dryer batches.
  • Usable dried resin capacity works out to 3,105 lb at these inputs, and this is the headline figure for the scenario.
  • Gross dryer output works out to 4,800 lb at these inputs.
  • Dryer uptime loss works out to 1,632 lb at these inputs.
  • Dry resin yield loss works out to 63.36 lb at these inputs.

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 28.26% below the baseline at 3,105 lb.
  • It computes usable dried resin capacity by multiplying batch size and batch count, then derating for dryer uptime and usable yield. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Usable dried resin capacity: 3,105 lb (headline result)
  • Gross dryer output: 4,800 lb
  • Dryer uptime loss: 1,632 lb
  • Dry resin yield loss: 63.36 lb

Run it with your numbers

  • To rerun this with your own numbers, open the live Resin Drying Load calculator, set dryer uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.