Material represents the single largest cost in almost any plastics processing operation.
If you have a machine processing 100 lb/hr (45 kg/hr) for 8,400 hours per year, that adds up to 840,000 lb or 450,000 kg. If you are processing engineering resins – hygroscopic materials that require proper drying in order to develop their full mechanical properties – the material for this one machine could be costing you millions of dollars per year. Next, add in labor, plant and equipment, and you begin to understand what it costs to mold or extrude every single pound of resin. These are truly mind-boggling numbers.
See related feature article, "Monitoring the Drying Process in Plastics Processing."