How to Calculate Filler Masterbatch Cost Savings per 100 Tons
How much can filler masterbatch save in a 100-ton PE film production run? This guide provides a transparent blend-cost calculation, explains the difference between masterbatch addition rate and mineral content, and shows why finished-film yield, density, thickness and scrap must be checked before claiming real savings.
Start With a Defined Cost Basis
Savings can be reported per kilogram of input blend, per tonne of film, per square metre of film or per thousand acceptable bags. These are not interchangeable. For a purchasing comparison, first calculate cost per kilogram of input blend. For a manufacturing decision, continue to cost per accepted product. State whether a 100-ton figure means 100 tonnes of input material or 100 tonnes of saleable output.
Basic Blend Cost Formula
For a two-component blend: blended material cost per kg = (resin fraction × resin price per kg) + (masterbatch fraction × masterbatch price per kg). Fractions must sum to 1. The masterbatch feed percentage is not the same as the mineral fraction inside that masterbatch. Use actual invoices or quotations, in the same currency and delivery basis, for both inputs.
Worked 100-Ton Example — Illustrative Prices Only
Assume PE resin costs US$1.20/kg and Na₂SO₄ filler masterbatch costs US$0.70/kg. At an 8% masterbatch feed rate, blended cost = 0.92 × 1.20 + 0.08 × 0.70 = US$1.160/kg. The baseline is US$1.200/kg, so the difference is US$0.040/kg or 3.33% of baseline material cost. For 100,000 kg of input blend, the theoretical raw-material saving is US$4,000. These prices are hypothetical, not Kovicrea quotations or verified customer savings.
Why the 100-Ton Calculation Is Not the Final Answer
If the filled film requires greater thickness to pass strength tests, uses more mass per square metre because of density changes, or generates more scrap, actual savings per finished bag may be lower. Conversely, stable processing and acceptable yield can help preserve the expected benefit. Compare equal performance specifications, not just equal input weights. Include production energy, screen changes and conversion waste if material changes affect them.
How to Measure Real Savings on the Production Line
Record resin and masterbatch consumption, output tonnes, average gauge, film width, run time, startup scrap, rejected rolls and accepted bags. Calculate total material spending divided by saleable output, then compare against a baseline period under similar operating conditions. Track customer complaints or downstream defects as delayed costs. A savings estimate should include a clear test period and sample size.
Sensitivity to Resin and Masterbatch Prices
The formula shows that savings change with the price difference between resin and masterbatch and with the addition rate. If the masterbatch costs nearly as much as resin, theoretical blend savings shrink. If filler dosage increases, quality and yield may become the limiting factors. Recalculate for the actual local market rather than copying a percentage from another factory, resin grade or month.
Request a Grade-Specific Cost Trial
Share your resin price, proposed masterbatch price, machine type, bag or film specification, planned dosage and current scrap rate. Kovicrea can discuss candidate Na₂SO₄ filler grades and sample testing. Confirm the final savings through a documented plant trial and evaluate cost per acceptable finished product.
Explore Related Technical Resources
Continue learning in the Kovicrea Technical Insights center, or compare application-oriented grades on our sodium sulfate filler masterbatch product page. For a broader overview, read our Na₂SO₄ filler masterbatch technical guide.