INJECTION MOLDING - COST SUMMARY

VARIABLE COSTS
Material Cost
Energy Cost
Labor Cost
Total Variable Cost
FIXED COSTS
Main Machine Cost
Auxiliary Equipment Cost
Tooling Cost
Fixed Overhead Cost
Building Cost
Maintenance Cost
Cost of Working Capital
Total Fixed Cost
Total Fabrication Cost

per piece
$7.82
$0.34
$0.33
$8.49

per year
$782,411
$33,741
$32,763
$848,915

percent
64.21%
2.77%
2.69%
69.67%

per piece
$0.84
$0.14
$1.13
$0.91
$0.49
$0.13
$0.05
$3.70

per year
$84,317
$14,053
$113,227
$91,060
$48,575
$13,009
$5,306
$369,547

percent
6.92%
1.15%
9.29%
7.47%
3.99%
1.07%
0.44%
30.33%

$12.18

$1,218,462

100.00%

RELATED VARIABLES
Material Requirements:
Raw Material Price
Trim Scrap Rate
Annual Material Input

$2.09 /kg
2.0%
374,359 kg

Process Calculations
Effective Production Volume
Run-Time for One Machine
Number of Parallel Streams
Number of tools required
Required Building Space
Energy Adjustment Factor

101,011
68%
0.68
1
305 sq m
1.53

Cycle Time Calculations

Predicted

Used

Cooling Time (sec)

Total Cycle Time (sec)

11.6
79.4

11.6
79.4

Predicted
20,996
$876,391
$429,220

Used
20,996
$876,391
$429,220

Press & Tool Characteristics & Costs

Clamping Force (kN)
Press Cost
Tool Cost

investment
$717,840
$119,640
$429,220
$457,914

$1,604,974

REGRESSION ANALYSIS DATA

EQUIPMENT REQUIREMENTS:
Mold Pressure Intercept
Mold Pressure Slope
EQUIPMENT COSTS:
Machine Cost Intercept
Machine Cost Slope
TOOL COSTS:
Weight Factor
Area Factor
Action Factor
Constant
CYCLE TIME:
Cooling Factor
Shot Weight Factor
Constant
BUILDING SPACE:
Floor Space Coefficient
Floor Space Scaling Exponent

172 bars
224 rt.cm bar

$14,829
$41 /kN

0.220
0.423
538
339

hr/g
hr/sq cm
hr
hr

2494
5176

$365

100
2.73

1.35
0.0151
8.87 sec

135 sq m
0.71

1453

MATERIAL DATABASE

psi
rt.in psi

/ton

hr/lb
hr/sq in

sq ft

Type
POLYSTYRENE
PVC (RIGID)
ABS
POLYPROPYLENE (HOMO)
NYLON 6
POLYCARBONATE
ACETAL (HOMO)
HDPE
POLYPHENYLENE ETHER
PET
THERMOPLASTIC POLYIMIDE
EVA
NYLON 6/30% GLASS
POLYCARBONATE/30% GLASS
ABS/20% GLASS
ACETAL/25% GLASS
PBT Alloy
PC/PBT
PC/PBT
PC
PPE
Blend
PA
PA
EVA CoPA
PA
Ionomer
LDPE
LDPE
LDPE
HDPE
HDPE
HDPE
PP CoPP CoPP Co-

EMPP
EMPP
EMPP
R-EMPP
ABS
ABS
ABS
ABS
ABS/PVC
PPE
PPE
PPE
PPE
ABS
ABS
ABS
ABS
ABS
ABS
TPO
TPO
TPE ester
TPE ester
TPU

Tradename

Valox
Xenoy
Xenoy
Lexan
Noryl
Noryl
Zytel
Zytel
Elvax
Bexloy
Bexloy
Suryln
Stamylan-LD
Stamylan-LD
Stamylan-LD
Stamylan-HD
Stamylan-HD
Stamylan-HD
Stamylan-P
Stamylan-P
Stamylan-P

Grade

830
1200
1101
141
844
GTX
ST-801
ST-901
960

2138GW00
2322GL00
2538EL00
7249
7058
5119
83MF10
412MN40
48M10

#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

Price
($/kg)
$2.33
$0.84
$2.22
$0.97
$4.38
$3.96
$3.43
$0.81
$2.93
$3.52
$11.88
$2.09
$4.27
$5.21
$2.38
$4.07
$3.26
$3.96
$3.74
$4.64
$2.66
$3.63
$5.06
$5.41
$1.50
$4.07
$4.40
$2.97
$0.73
$0.73
$0.73
$0.81
$0.81
$0.81
$0.93
$0.87
$0.87

XML
1.00
0.80
1.00
1.05
1.00
0.85
0.90
1.00
0.98
0.90
1.00
1.05
1.00
0.75
0.80
0.80
0.85
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.10
1.00
1.00
1.05
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20

XSC
1.00
1.00
1.00
1.00
1.00
1.00
1.10
1.00
1.00
1.20
1.11
1.00
1.10
1.25
1.11
1.10
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

Keltan TP
Keltan TP
Keltan TP
Kelburon
Ronfalin
Ronfalin
Ronfalin
Ronfalin
Ronfalin
Prevex
Prevex
Prevex
Prevex
Cycolac
Cycolac
Cycolac
Cycolac
Cycolac
Cycolac
Ontex
Dexflex
Lomod
Bexloy
Estane

0603
0505
2607
90594
FX
TX
HX
VE
RN-03
PMA
PQA
VJA
W30
T
GSM
L
DFAR
DH
KJB
111BX
850
521
V

38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79

$1.83
$1.93
$1.73
$1.89
$2.13
$2.24
$2.24
$2.72
$2.64
$3.43
$4.29
$3.76
$3.76
$2.50
$2.53
$2.60
$2.35
$2.42
$2.99
$2.97
$2.09
$3.74
$3.63
$4.62

1.20
1.20
1.10
1.20
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.25
1.25
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

XAU
1.00
1.00
1.10
1.00
1.30
1.20
1.20
1.00
1.20
1.30
1.30
1.00
1.30
1.30
1.20
1.20
1.30
1.30
1.30
1.30
1.20
1.16
1.30
1.30
1.00
1.30
1.30
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

XMA
1.00
1.00
1.00
1.00
1.10
1.10
1.00
1.00
1.00
1.05
1.00
1.00
1.30
1.30
1.30
1.25
1.30
1.00
1.00
1.10
1.00
1.00
1.30
1.30
1.00
1.30
1.30
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

Temp
Melt
204
177
246
246
260
282
218
218
274
302
343
163
271
316
218
221
254
292
292
300
274
257

180
220
180
200
240
200
260
210
220

Temp
Tool

Temp
Eject
35
35
35
35
45
55
45
35
45
45
65
30
45
55
35
45
80
50
50
93
45
41

70
65
70
65
80
80
80
55
75
80
100
50
85
80
80
85
120
80
80
110
75
74

40
40
40
40
40
40
40
40
40

50
55
50
70
70
60
78
88
88

k
(W/mK)
0.13
0.18
0.25
0.12
0.24
0.20
0.23
0.48
0.19
0.15
0.10
0.38
0.24
0.22
0.27
0.25
0.29
0.17
0.17
0.19
0.19
0.15

Cp
(J/kgK)
1340
1400
1500
1925
1675
1260
1470
2300
1340
1715

0.32
0.32
0.32

2300
2300
2300
2300
2300
2300
1680
1680
1680

0.22
0.22
0.22

2300
1255

1488
1488
1250
1450

1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.20
1.20
1.20
1.20
1.10
1.10
1.10
1.10
1.10
1.10
1.00
1.00
1.15
1.15
1.15

1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.10
1.20
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.05
1.05
1.05
1.05

240
240
240
240
220
240
265
230
210
275
290
265
275
246
246
250
242
246
223
240
240
232
232
204

35
35
35
35
40
50
60
50
50
77
100
70
77
52
52
52
52
71
63
35
35
45
45
52

70
70
70
70
90
94
105
85
78
95
115
95
95
85
85
85
85
90
85
70
70
80
80
80

0.22
0.22
0.24
0.22
0.25
0.25
0.25
0.25
0.22
0.19
0.19
0.19
0.19
0.25
0.25
0.25
0.25
0.25
0.25
0.22
0.22
0.15
0.15
0.15

2000
2800
2400
2000
1500
1500
1500
1500
1450
1340
1340
1340
1340
1500
1500
1500
1500
1500
1500
2000
2000
1715
1715
1715

Specific
Gravity
1.050
1.350
1.050
0.900
1.130
1.200
1.400
0.950
1.080
1.370
1.400
0.920
1.380
1.400
1.220
1.610
1.540
1.200
1.210
1.200
1.060
1.150

0.921
0.923
0.925
0.952
0.952
0.943
0.905
0.905
0.905

0.895
0.890
1.050
0.900
1.060
1.060
1.060
1.280
1.260
1.060
1.060
1.100
1.060
1.040
1.040
1.020
1.040
1.050
1.220
1.040
0.900
1.200
1.200
1.100