Single-Use Bioprocess Assemblies worked example

Sterilization Load with sterilizer connected electrical load of 30 kW: a worked example in single-use bioprocess assemblies

This scenario runs the sterilization load calculation on the strong side: sterilizer connected electrical load of 30 kW, with every other input held at its documented default. Use it when sterilization load in single-use bioprocess assemblies is up for an upgrade and you want a defensible savings story.

The inputs for this scenario

  • Sterilizer connected electrical load: 30 kW (raised for this scenario; the documented default is 12)
  • Sterilization cycle runtime: 8 hr (unchanged)
  • Blended plant electricity rate: 0.12 $ / kWh (unchanged)
  • Assemblies processed per cycle: 1,000 units (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where sterilizer connected electrical load sits at 12 kW and the headline result is 96 kWh, this scenario comes in 150% above the baseline at 240 kWh.
  • Use it when building a batch cost model, benchmarking sterilizer efficiency, or deciding whether to consolidate small loads into fuller runs. 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

  • Sterilization load energy used: 240 kWh (headline result)
  • Total sterilization load energy cost: 28.8 $
  • Energy cost per kWh: 0.03 $ / piece
  • Hourly sterilization load energy cost: 3.6 $ / hr

Run it with your numbers

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

Last reviewed 2026-05-12.