Savings Calculator

What could your line gain?

Estimate the annual value of less scrap, lower material or energy consumption, and higher output. Choose your process and adjust the assumptions to your production line.

Choose your process

Number of lines

Enter the values below per line. Annual potential is the combined total for the selected number of comparable lines.

Your production line

Reset example

Example line data – replace with your own values

Your scenario – annual estimate

Average material flow while running, including scrap.

Including scrap. Linked to gross throughput × operating hours ÷ 1,000. You can edit either value.

Actual running hours for one line, excluding downtime. Changing hours updates whichever linked value you did not enter last.

Blended material cost, including additives.

Electricity consumed per kilogram of gross material input at current operating conditions.

Your variable electricity cost per kWh.

Annual electricity use: –

01 · Scrap rate reduction

Share of gross material input classified as scrap.

Target scrap rate 
calculated
–

Current production scrap rate × (1 − relative reduction).

80% is a realistic starting point based on reductions achieved with jora.twin in previous projects. Results depend on your line.

02 · Meter Weight Reduction

Less material per metre, at unchanged product length and within product specifications.

02 · Energy consumption reduction

Relative reduction in electricity use for your baseline production volume.

03 · Output increase

Independent increase at unchanged running hours, excluding gains already counted above.

Selling price minus all variable costs, including material and energy, per current saleable kg.

Assumes 100% of additional output can be sold.

Extrusionannual value:–. Target scrap rate:–%.

Example inputs restored for extrusion.

How the calculation works

Scrap rate reduction. Annual material input = gross throughput × operating hours. You can enter the annual input in tonnes or the throughput in kg/h; the other value is calculated automatically. Target scrap rate = current production scrap rate × (1 − relative reduction). For example, 5% current scrap with an 80% reduction gives 1% target scrap. At the same saleable output, a lower scrap rate reduces required material input. Avoided scrap is valued at the material price; recovery value is assumed to be zero.

Meter Weight Reduction. Applied after the scrap improvement, at the same product length. The reduced material input is valued at material price. This sequential calculation keeps the two material savings separate and assumes selling value per metre stays unchanged.

Energy consumption reduction. Baseline annual electricity use = gross throughput × operating hours × specific electricity use. Multiply this by the relative energy reduction and electricity price. No additional energy credit is added for reduced scrap.

Output increase. Current saleable output × line speed or throughput increase × contribution margin. All additional output is assumed to be sold. Only an independent throughput gain is counted; capacity freed by other improvements is not counted again. No further material or energy savings are credited to this added output.

Annual steady-state estimate per line with an unchanged product mix, multiplied by the selected number of comparable lines. Excludes ramp-up, changes in fixed costs, software, implementation and tax. Values are gross business potential, not net ROI or payback. The scrap reduction reference comes from previous jora.twin projects; other example values are adjustable assumptions, not guaranteed performance. Extrusion output is expressed at current meter weight.