Quantify the bottom-line impact of optimizing your extrusion process. Use our free calculator to determine your return on investment (ROI) from material savings, reduced scrap, and improved web handling.
GAUGE ADVISOR TOOL
Annual Material Giveaway Savings: $0.00
Annual Scrap Reduction Savings: $0.00
Annual Labor Savings: $0.00
Total Annual Savings: $0.00
Estimated ROI Period (Payback): N/A Years
Net Present Value (NPV): $0.00
Annual Break/Defect Savings: $0.00
Annual Downtime Labor Savings: $0.00
Annual Maintenance Savings: $0.00
Total Annual Savings: $0.00
Estimated ROI Period (Payback): N/A Years
Net Present Value (NPV): $0.00
Your ROI calculation provides a clear financial roadmap for process improvement. The two tabs of the calculator focus on distinct operational areas, each offering substantial, quantifiable savings:
This tab focuses on the capital justification for non-contact thickness gauges and automatic die control (ADC) systems. In film and sheet production, material savings are king.
In high-speed production, even minor tension fluctuations lead to catastrophic failures. Consistent web tension control (using high-accuracy strain gauges) drives profitability by:
In film and sheet extrusion, success is measured in microns and dollars per pound. Even marginal inconsistencies in thickness (gauge) or poor web handling can erase profit margins, especially when dealing with expensive specialty resins.
Our Film & Sheet Measurement ROI Calculator helps plant managers and engineers move beyond simple equipment costs to calculate the true long-term value of a quality control system. We break down savings into two core areas:
Use the calculation tool above to estimate your operational cost savings and projected payback period for upgrading your in-line quality assurance systems.
The ROI calculator provides the “Why.” Gauge Advisor provides the “How.”
A significant calculated ROI is your internal justification for capital expenditure. We don’t just supply equipment; we partner with you to select, integrate, and optimize the right measurement and control systems—whether that’s a laser thickness gauge, an X-ray system, or a high-performance web tension sensor.
Q: What is “Material Giveaway” in extrusion and why is it so costly? A: Material Giveaway (or over-gauge) is the excess material extruded above the target thickness to ensure the product never violates the minimum tolerance. Because raw material is the dominant cost in film/sheet production, running even 1% over-gauge can cost hundreds of thousands of dollars annually. Precision thickness measurement eliminates this necessity.
Q: How quickly can a company see a payback on a new thickness control system? A: Due to the high cost of resin, it’s common for companies with moderate to high production volumes to see a payback period of 12 to 24 months on advanced thickness measurement and automatic die control (ADC) systems, purely from material savings.
Q: What is the main benefit of measuring web tension using strain gauges? A: The main benefit is improved quality and yield in the final slitting or winding stage. Accurate web tension prevents common defects like telescoping (uneven winding), wrinkles, and baggy edges, ensuring the product passes quality control and reduces costly customer claims.
