Thermoforming & Vacuum Formed Products worked example

Scrap Cost at 58% share of part value unrecoverable at scrap: a worked example in thermoforming & vacuum formed products

Here is what the math looks like when conditions slip. We hold every other input steady and drop share of part value unrecoverable at scrap to 58%, then walk the calculation through step by step. Scrap Cost quantifies the money lost to rejected formed parts, weighted by how much of each part's value you can never recover after trimming, forming, and decoration.

The inputs for this scenario

  • Scrapped formed parts in the run: 100 units (held at the documented default)
  • Value lost per scrapped part: 45 $ / unit (held at the documented default)
  • Share of part value unrecoverable at scrap: 58 % (the input this scenario stresses; the baseline uses 80)
  • Fixed scrap-handling and regrind overhead: 250 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Scrap Cost cost = quantity × rate × capture factor + fixed cost.
  • Weighted cost works out to 2,860 $ at these inputs, and this is the headline figure for the scenario.
  • Per piece value works out to 28.6 $ / piece at these inputs.
  • Captured value works out to 2,610 $ at these inputs.
  • Fixed adjustment works out to 250 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where share of part value unrecoverable at scrap sits at 80% and the headline result is 3,850 $, this scenario comes in 25.71% below the baseline at 2,860 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to share of part value unrecoverable at scrap, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The capture factor is an estimate of how much value is genuinely lost; regrind value, contamination limits and material blend all shift it, so audit that percentage against real reclaim data.

Results at a glance

  • Weighted cost: 2,860 $ (headline result)
  • Per piece value: 28.6 $ / piece
  • Captured value: 2,610 $
  • Fixed adjustment: 250 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Scrap Cost calculator, set share of part value unrecoverable at scrap to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.