Rubber, Tires, Foam & Elastomer Manufacturing worked example

Batch Mixing Energy with mixer connected load of 6 kW: a worked example

This worked example runs the batch mixing energy numbers for a tougher week than the baseline: mixer connected load of 6 kW instead of the typical 12 kW. Estimate batch mixing energy for rubber, tires, foam and elastomer manufacturing using production-ready inputs so teams can budget energy cost, compare equipment settings, or include electricity in the quote.

The inputs for this scenario

  • Mixer connected load (motor + heaters): 6 kW (the input this scenario stresses; the baseline uses 12)
  • Mixing cycle runtime per batch series: 8 hr (held at the documented default)
  • Blended plant electricity rate: 0.12 $ / kWh (held at the documented default)
  • Compound units produced during runtime: 1,000 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total batch mixing energy cost = batch mixing energy connected load × batch mixing energy runtime × blended electricity rate.
  • Total batch mixing energy cost works out to 5.76 $/unit at these inputs, and this is the headline figure for the scenario.
  • Batch mixing energy used works out to 48 kWh at these inputs.
  • Energy cost per $ works out to 0.01 $ / piece at these inputs.
  • Hourly batch mixing energy cost works out to 0.72 $ / hr at these inputs.

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 50% below the baseline at 5.76 $/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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total batch mixing energy cost: 5.76 $/unit (headline result)
  • Batch mixing energy used: 48 kWh
  • Energy cost per $: 0.01 $ / piece
  • Hourly batch mixing energy cost: 0.72 $ / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Batch Mixing Energy calculator, set mixer connected load to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.