How do you calculate coating rework cost?

Multiply quantity by rate by the yield capture factor, then add fixed cost. For 100 tools at $45, 80% capture and $250 fixed: 100 x 45 x 0.80 + 250 = $3,850 total, or $38.50 per piece.

What does the yield capture factor represent?

The share of the per-tool rate you actually recover after coating rejects and touch-ups. At 80% it discounts the gross $4,500 variable down to $3,600 captured before fixed cost.

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, $38.50 here, sits well below a new coated tool's price. If a new tool is $120, recoating at $38.50 is an easy win; if it is $45, 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 captured 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, blending a per-tool rate scaled by a yield factor with 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 and the yield capture factor, adds fixed cost for the total, then divides by quantity for a per-piece coating rework cost.

Formula used

Coating Rework Cost cost = quantity × rate × capture factor + fixed cost
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 by the yield capture factor, then add fixed cost. For 100 tools at $45, 80% capture and $250 fixed: 100 x 45 x 0.80 + 250 = $3,850 total, or $38.50 per piece.
What does the yield capture factor represent? The share of the per-tool rate you actually recover after coating rejects and touch-ups. At 80% it discounts the gross $4,500 variable down to $3,600 captured before fixed cost.
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, $38.50 here, sits well below a new coated tool's price. If a new tool is $120, recoating at $38.50 is an easy win; if it is $45, 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 captured cost per tool.

Last reviewed 2026-05-12.