How do you calculate coating rework cost?

Multiply quantity by rate and divide by the yield capture factor, then add fixed cost. For 100 tools at $45, 80% capture and $250 fixed: 100 x 45 / 0.80 + 250 = $5,875 total, or $58.75 per piece.

What does the yield capture factor represent?

The share of coating passes that come out right the first time. At 80% the gross $4,500 variable loads up to $5,625 before fixed cost, because rejected tools go back through strip and recoat on your line time.

Why does per-piece cost depend on batch size?

The $250 fixed setup spreads across every tool. On 100 tools it adds $2.50 each; on 50 it would add $5.00, so bigger chamber loads lower the per-piece cost.

When is recoating cheaper than replacing?

When the per-piece recoat cost, $58.75 here, sits well below a new coated tool's price. If a new tool is $120, recoating at $58.75 is a clear win; if it is $65, the margin is thin.

What is a good yield capture factor for a coating line?

Well-run PVD and TiAlN lines capture 85-95%; frequent stripping rejects or edge-prep problems can pull it to 70-80%, directly raising the loaded cost per tool.

Should fixed cost include stripping chemicals?

Put per-batch charges like chamber load and gas fills in fixed cost, and per-tool consumables like strip acid in the rate. Mixing them distorts how per-piece cost scales with batch size.

Tool Sharpening, Reconditioning & Industrial Repair Services calculator

Coating Rework Cost Calculator

Coating Rework Cost totals what it costs to strip and recoat a batch of tools after regrinding, blending a per-tool rate scaled by a yield factor with a fixed setup charge. Estimators and tool room managers use it to price recoating jobs and to decide whether recoating a worn tool beats replacing it. Because coating lines carry a fixed chamber-load cost plus a per-tool variable, the per-piece cost falls as batch size rises, which this calculator makes explicit. That per-piece number is what you quote and what you compare against a new tool's price.

What this calculator does

Coating Rework Cost totals what it costs to strip and recoat a batch of tools after regrinding, loading a per-tool rate for coating rejects and adding a fixed setup charge.
Use it when coating rework cost in tool sharpening, reconditioning and industrial repair services is being put through a tool sharpening, reconditioning and industrial repair services weighted-cost review.
It multiplies quantity by rate, divides by the yield capture factor because rejects consume extra strip-and-recoat passes, adds fixed cost for the total, then divides by quantity for a per-piece coating rework cost.

Formula used

Coating rework cost = tools recoated × rate per tool ÷ yield capture% + fixed batch setup
Per-unit coating rework cost = total cost ÷ quantity

Inputs explained

Tools recoated in the batch:
Coating rework rate per tool:
Yield capture factor:
Fixed batch setup cost:

How to use the result

Use it when quoting a recoating job or deciding recoat versus replace on reground tools.
The yield capture factor is a single blended number; a batch with widely varying reject rates by tool type will skew the per-piece figure unless split.

Common questions

How do you calculate coating rework cost? Multiply quantity by rate and divide by the yield capture factor, then add fixed cost. For 100 tools at $45, 80% capture and $250 fixed: 100 x 45 / 0.80 + 250 = $5,875 total, or $58.75 per piece.
What does the yield capture factor represent? The share of coating passes that come out right the first time. At 80% the gross $4,500 variable loads up to $5,625 before fixed cost, because rejected tools go back through strip and recoat on your line time.
Why does per-piece cost depend on batch size? The $250 fixed setup spreads across every tool. On 100 tools it adds $2.50 each; on 50 it would add $5.00, so bigger chamber loads lower the per-piece cost.
When is recoating cheaper than replacing? When the per-piece recoat cost, $58.75 here, sits well below a new coated tool's price. If a new tool is $120, recoating at $58.75 is a clear win; if it is $65, the margin is thin.
What is a good yield capture factor for a coating line? Well-run PVD and TiAlN lines capture 85-95%; frequent stripping rejects or edge-prep problems can pull it to 70-80%, directly raising the loaded cost per tool.

Last reviewed 2026-08-12.