XPS LINE OUTPUT CALCULATOR
XPS LINE OUTPUT
CALCULATOR
HAUL-OFF SPEED TO KG/H
Haul-Off Speed
i
The speed your puller is running right now.
Edge Trim / Side
i
Width milled off each side edge of the board. It is removed from both sides.
mm
Thickness
i
Board thickness as it leaves the calibrator.
Board Width
i
Full width of the foam board as it leaves the calibrator, before any edge trimming.
Use the width before trimming
Foam Density (from a Sample)
i
Cut a regular block from a finished board and measure it.
L: sample length. W: sample width. T: sample thickness. Weight: sample weight on a scale. Use a fully aged board so the blowing agent has left.
L: sample length. W: sample width. T: sample thickness. Weight: sample weight on a scale. Use a fully aged board so the blowing agent has left.
L
W
T
Size in
Weight
Calculated density
—
Board & Shift Setup
i
Cut length: length of each finished board. Efficiency: share of shift time the line is actually running. Shift: hours in one shift. Shifts/day: number of shifts you run per day. Days/month: production days per month.
Cut (m)
Eff. %
Shift (h)
Shifts/day
Days/month
Optional: Extruder & Material
Screw Speed
i
Rotation speed of the main extruder screw.
RPM
Max Capacity
i
Maximum melt output the extruder is rated for.
kg/h
Blowing Agent
i
Share of the total melt that is blowing agent. It leaves the board after extrusion.
%
Additives
i
Share of the finished foam that is additives (flame retardant, colorant, nucleator and so on).
%
Raw Material Price
i
Average cost of one kilogram of your polymer and additives blend, in your own currency.
per kg
Line Output (Gross)
i
Total foam material the line produces every hour, edges included.
0.0
kg/h
0.00 kg/min
Net Sellable Output
i
Finished board material per hour after both side edges are trimmed off.
0.0 kg/h
Net width 0 mm | trim loss 0.0%
Regrind from Edge Trim
i
Trimmed edge material per hour that goes back to the grinder.
0.0 kg/h
0.0% of line output
Foam & Web
Foam Densityi
Weight of one cubic meter of finished foam, taken from your sample.
—
Foam Volumei
Volume of foam the line produces per hour.
—
Linear Weighti
Weight of one meter of full-width board.
—
Net Areai
Surface area of finished trimmed board produced per hour.
—
Board & Saw
Board Weighti
Weight of one finished, trimmed board.
—
Boards / Houri
Number of boards cut each hour while the line runs.
—
Saw Cyclei
Time between two saw cuts.
—
Cost / Boardi
Raw material cost of one finished board, including the trimmed edges.
—
Production Totals (Sellable)
Per Shifti
Finished board produced in one shift, with line efficiency applied.
—
Per Dayi
Finished board produced in one production day.
—
Per Monthi
Finished board produced in one production month.
—
Material Usedi
Total raw material consumed per shift, including the trimmed edges.
—
per shift
Extruder & Material
Total Melti
Everything the extruder pushes through the die: polymer, additives and blowing agent.
—
Extruder Loadi
How much of the extruder's maximum capacity the line is using. Needs Max Capacity.
—
Specific Outputi
Melt delivered per screw revolution. A sudden drop at constant speed signals a feed or wear problem. Needs Screw Speed.
—
Material Costi
Raw material cost per hour. Needs Raw Material Price.
—
Polymeri
Polymer fed per hour, for resin dosing.
—
Additivesi
Additives fed per hour, for masterbatch dosing.
—
Blowing Agenti
Blowing agent injected per hour, for injection pump setting.
—
Tips for Accurate Results
- Measure the board width before any edge trimming.
- Take the density sample from a fully aged board, away from the skin and the edges.
- Check the real puller speed on the display while the line is stable.
When the Result Looks Off
- Compare the calculated output with your gravimetric feeder reading.
- A large gap usually means a wrong density sample or a wrong width.
More Engineering Tools
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Expansion Ratio & Blowing Agent Injection Calculator
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Interactive Extrusion Troubleshooting Wizard
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Industrial Polymer Engineering Unit Converter
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About This XPS Line Output Calculator
The XPS Line Output Calculator tells plastic extrusion engineers and line operators how many kilograms of material an XPS foam board line produces per hour at a given haul-off speed. It also reports net sellable output, edge trim regrind, boards per shift, extruder load and raw material cost.
