Transformers, Coils & Magnetics Manufacturing worked example

Varnish Usage at 61% application transfer efficiency: a worked example

This worked example runs the varnish usage numbers for a tougher week than the baseline: 61% application transfer efficiency instead of the typical 85%. This calculator sizes the impregnation or dip varnish a coil batch actually consumes once you account for drag-out, drips, tank cling and cure-oven losses.

The inputs for this scenario

  • Coils to be varnish-impregnated: 500 units (held at the documented default)
  • Varnish per coil (theoretical): 0.08 units (held at the documented default)
  • Application transfer efficiency: 61 % (the input this scenario stresses; the baseline uses 85)

Working through the calculation

  • The calculation starts from the formula this tool documents: Required varnish usage = covered amount × use per unit ÷ transfer efficiency.
  • Required quantity works out to 65.57 units at these inputs, and this is the headline figure for the scenario.
  • Theoretical amount works out to 40 units at these inputs.
  • Loss allowance works out to 25.57 units at these inputs.
  • Efficiency works out to 61 % at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where application transfer efficiency sits at 85% and the headline result is 47.06 units, this scenario comes in 39.34% above the baseline at 65.57 units.
  • Use it when ordering varnish for a batch, setting impregnation tank levels, or budgeting consumable cost per transformer run. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Required quantity: 65.57 units (headline result)
  • Theoretical amount: 40 units
  • Loss allowance: 25.57 units
  • Efficiency: 61 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Varnish Usage calculator, set application transfer efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.