Specialty Films, Membranes & Barrier Materials worked example

Roll Scrap Cost at 98% unrecoverable share: a worked example in specialty films, membranes & barrier materials

What does the result look like when unrecoverable share reaches 98%? The full calculation is worked below with real intermediate numbers. A converting plant prices its roll scrap to target the biggest yield-loss source on a barrier film line.

The inputs for this scenario

  • Scrapped film length: 3,000 linear meters (unchanged)
  • Loaded film value: 0.85 $/linear meter (unchanged)
  • Unrecoverable share: 98 % (raised for this scenario; the documented default is 85)
  • Disposal and handling fee: 300 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total roll scrap = scrapped length x loaded value x unrecoverable share + disposal fee) to the inputs above produces each figure below.
  • At this operating point the engine returns 2,799 $ for total roll scrap cost, the number this scenario is built around.
  • At this operating point the engine returns 0.93 $ / piece for roll scrap cost per unit.
  • At this operating point the engine returns 2,499 $ for variable roll scrap cost.
  • At this operating point the engine returns 300 $ for fixed roll scrap cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where unrecoverable share sits at 85% and the headline result is 2,468 $, this scenario comes in 13.43% above the baseline at 2,799 $.
  • A figure at this level is achievable when unrecoverable share is genuinely sustained, not just peaked for a shift. It uses one blended loaded value per meter, so it will misprice scrap when startup waste (low value) and finished coated web (high value) are lumped together at a single rate.

Results at a glance

  • Total roll scrap cost: 2,799 $ (headline result)
  • Roll scrap cost per unit: 0.93 $ / piece
  • Variable roll scrap cost: 2,499 $
  • Fixed roll scrap cost adder: 300 $

Run it with your numbers

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

Last reviewed 2026-05-12.