Finishing worked example

Powder Reclaim Savings with recoverable overspray parts of 250 parts: a worked example

What does the result look like when recoverable overspray parts reaches 250 parts? The full calculation is worked below with real intermediate numbers. Use this calculator for practical powder coating or surface finishing planning, quoting, troubleshooting, or line setup.

The inputs for this scenario

  • Recoverable overspray parts: 250 parts (raised for this scenario; the documented default is 100)
  • Virgin powder replacement cost: 2.5 $ / part (unchanged)
  • Reclaim handling labor: 150 $ (unchanged)
  • Waste disposal avoided: 75 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total cost = quantity × unit cost + labor/downtime + overhead) to the inputs above produces each figure below.
  • At this operating point the engine returns 850 $ / shift for total cost, the number this scenario is built around.
  • At this operating point the engine returns 3.4 $ / piece for cost per piece.
  • At this operating point the engine returns 625 $ for variable cost.
  • At this operating point the engine returns 225 $ for fixed adders.

How this compares with the baseline

  • Against the tool's baseline example, where recoverable overspray parts sits at 100 parts and the headline result is 475 $ / shift, this scenario comes in 78.95% above the baseline at 850 $ / shift.
  • A figure at this level is achievable when recoverable overspray parts is genuinely sustained, not just peaked for a shift. Reclaimed powder can drift in particle size and charge behavior over recycle cycles; it treats every recovered part-equivalent as fully reusable, which overstates savings for fine-tuned metallics.

Results at a glance

  • Total cost: 850 $ / shift (headline result)
  • Cost per piece: 3.4 $ / piece
  • Variable cost: 625 $
  • Fixed adders: 225 $

Run it with your numbers

  • Every input above is editable in the live Powder Reclaim Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.