FPV & Back Pressure Monetary Saving Calculator

What This Tool Does

Every masterbatch supplier claims better quality. This calculator proves it with an annual saving figure in IDR that customer can verify, approve, and act on.

Built on established injection moulding physics, it translates two trial measurements on the customer's machine into a complete economic comparison between incumbent and prospect masterbatch.

Two Saving Arguments, Automatically Calculated

Argument 1 - LDR Saving

Better dispersion → same colour at lower let-down ratio → less masterbatch consumed per kg of resin. Calculated from trial LDR versus the incumbent's current LDR, multiplied by annual resin volume.

Argument 2 - Cycle Time Saving

Lower FPV masterbatch → lower back pressure needed → shorter screw recovery time → shorter cycle time → more parts per hour. The calculator automatically checks whether screw recovery is on the critical path before showing this saving, no false claims.

Both savings are shown separately and combined against the price premium to produce a single net annual saving verdict.

Key Features

Critical path check - automatically determines whether reducing back pressure will actually shorten cycle time on this specific machine. If cooling time is the bottleneck, the calculator flags this and shifts the argument to LDR saving only.

FPV as quality credential - enter FPV (EN 13900-5 test certificate) alongside the trial data. The ΔFPV is displayed as the scientific explanation of why back pressure differs between the two masterbatches.

Incumbent FPV optional - commodity suppliers rarely disclose FPV. The monetary calculation runs entirely on measured machine data. FPV is shown where available and marked as context only.

Auto-generated business case narrative - one paragraph ready to paste into a proposal or email to the customer's purchasing team. Updates live as you enter data.

φ Operator Prediction Tool - from the same two trial measurements, the calculator derives φ (screw pressure sensitivity), a machine and resin constant. Use it to predict screw recovery time at any back pressure setting without running additional trials, or to find the maximum back pressure for a target cycle time.

Machine hourly rate sub-calculator - derive IDR/hr from depreciation, maintenance, energy, and overhead components if the customer's rate is unknown.

Dual cycle timing input - works whether the customer's machine displays screw recovery time directly on the HMI, or only shows total cycle time.

Who This Is For

• Masterbatch sales engineers justifying a price premium to injection moulding customers

• Process engineers evaluating masterbatch supplier changes

• Production managers quantifying the cost of running suboptimal process settings

Technical Basis

The monetary calculation is fully empirical anchored entirely to your measured machine data, with no assumed constants. FPV provides the scientific explanation of why back pressure differs; the Rupiah saving comes from the measured difference in screw recovery time.

All assumptions and limitations are documented inside the calculator's methodology section.

License

Single-user license. Key is registered to your email address and valid for one calendar year. Annual renewal required.