LF-Sizer Payback Case Study

             
Automatic Layflat Control Payback  
   
16" Die running an average of 48 inch layflat  
   
Before - no control system 30 Days  
Gross 108,320 lbs Annual Overage Loss  
Scrap 4,320 lbs Net Saleable Overage Loss  
Net Saleable 104,000 lbs 1,248,000 13,000 $11,830.00  
Layflat Variation - Total 0.5 Inches  
Scrap percent of Gross 3.99%  
   
After Install of LF-Sizer from DRJ 30 Days  
Gross 116,444 lbs Annual Overage Loss  
Scrap 4,156 lbs Net Saleable Overage Loss  
Net Saleable 112,288 lbs 1,347,458 7,018 $6,386.39  
Layflat Variation - Total 0.25 Inches  
Scrap percent of Gross 3.57%  
   
Assumptions (Adjust blue values as req'd)  
Production Gain with LF-Sizer 7.50%  
Average Layflat 48 Inches  
Average Material Cost per Pound $0.91  
Average Thickness 0.00075 Inches  
Resin to Scrap Value per Pound $0.20  
Margin (dollars per pound) $0.157  
   
Annual Savings and Improvements NOTES:  
Layflat Savings $5,443.61 Savings from less overage  
Scrap Savings $393.98 Savings from less scrap  
Net Saleable Improvement $15,614.89 Benefit from more net saleable  
Total Savings $21,452.49  
   
Estimated Payback for System  
Purchase Cost of System (4 Sensors) $14,660.82 4 Sensor system with modem  
Commissioning & Travel (Req'd on first unit) $460.00 DRJ Technician   
Sensor Supports (only if nothing exists) $600.00 Aluminum Frame Fabrication  
Installation Excluding Support (4 Man hours) $200.00 Installation of standard system  
Total Installed Cost $15,920.82  
   
Payback 8.906 Months