Rubber, Tires, Foam & Elastomer Manufacturing worked example

Batch Mixing Energy with mixer connected load of 30 kW: a worked example

This scenario runs the batch mixing energy calculation on the strong side: mixer connected load of 30 kW, with every other input held at its documented default. Use it when batch mixing energy in rubber, tires, foam and elastomer manufacturing is up for an upgrade and you want a defensible savings story.

The inputs for this scenario

  • Mixer connected load (motor + heaters): 30 kW (raised for this scenario; the documented default is 12)
  • Mixing cycle runtime per batch series: 8 hr (unchanged)
  • Blended plant electricity rate: 0.12 $ / kWh (unchanged)
  • Compound units produced during runtime: 1,000 units (unchanged)

Working through the calculation

  • Applying the documented formula (Total batch mixing energy cost = batch mixing energy connected load × batch mixing energy runtime × blended electricity rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 28.8 $/unit for total batch mixing energy cost, the number this scenario is built around.
  • At this operating point the engine returns 240 kWh for batch mixing energy used.
  • At this operating point the engine returns 0.03 $ / piece for energy cost per $.
  • At this operating point the engine returns 3.6 $ / hr for hourly batch mixing energy cost.

How this compares with the baseline

  • Against the tool's baseline example, where mixer connected load sits at 12 kW and the headline result is 11.52 $/unit, this scenario comes in 150% above the baseline at 28.8 $/unit.
  • Use it when quoting a new compound, comparing mixer cycle recipes, or building an energy-per-unit baseline before an off-peak or demand-charge review. 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

  • Total batch mixing energy cost: 28.8 $/unit (headline result)
  • Batch mixing energy used: 240 kWh
  • Energy cost per $: 0.03 $ / piece
  • Hourly batch mixing energy cost: 3.6 $ / hr

Run it with your numbers

  • Every input above is editable in the live Batch Mixing Energy calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.