Thermoforming & Vacuum Formed Products worked example

Energy Per Sheet with former connected load of 30 kW: a worked example

This scenario runs the energy per sheet calculation on the strong side: former connected load of 30 kW, with every other input held at its documented default. Use it when energy per sheet in thermoforming and vacuum formed products is being quoted and energy is a real chunk of the thermoforming and vacuum formed products cost stack.

The inputs for this scenario

  • Former connected load (heaters, vacuum pump, motors): 30 kW (raised for this scenario; the documented default is 12)
  • Production runtime for the batch: 8 hr (unchanged)
  • Electricity rate: 0.12 $ / kWh (unchanged)
  • Formed sheets produced in the batch: 1,000 units (unchanged)

Working through the calculation

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

How this compares with the baseline

  • Against the tool's baseline example, where former 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 formed-part program, comparing machine efficiency, or building an energy-per-part baseline before a heater or insulation upgrade. 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

  • Energy cost: 28.8 $ / unit (headline result)
  • Energy used: 240 kWh
  • Cost per piece: 0.03 $ / piece
  • Hourly cost: 3.6 $ / hr

Run it with your numbers

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

Last reviewed 2026-05-12.