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Roll Fed Versus In-Line Thermoforming

Roll Fed Versus In-line Thermoforming for a Dairy Package

• Converters manufacture most high volume containers via the in-line thermoforming process. Most lines are post trim.
• Critical tolerances at the seal on dairy packages require trim in place thermoforming technology.
• Dairy packages are high volume parts. Presently they are manufactured by roll fed and/or in-line thermoforming.
• Manufacturing cost comparison follows.

Click here to see the FT 8000 Analysis

 

Extrusion Rate: 3100 lb/HR Ft 8000 Thermoformer Mold Size: 35' x 40' (Cavitation = 80) Summary of operating cost/hour (w/o polymer $)
Cost Component	Roll Fed($/HR)		In-Line(S/HR)
Factory Floor Space	16		11
Labor	160		120
Power	140		114
Depreciation	130		127
MRO	20		20
Total	466		392
Cost per 1000 parts
Operating Costs	466		392
CPM	16.2		18
Efficiency	0.8		0.8
Part per hour	62,210		69,120
Cost per 1000 Parts	7.49		5.66
In-Line Cost Savings		24%

 

Click here to see the FT 3500 Analysis

 

Extrusion Rate: 1700 lb/HR Ft 3500 Thermoformer Mold Size: 30' x 18' (Cavitation = 32) Summary of operating cost/hour (w/o polymer $)
Cost Component	Roll Fed($/HR)		In-Line(S/HR)
Factory Floor Space	14		10
Labor	160		120
Power	86		71
Depreciation	84		82
MRO	20		20
Total	364		303
Cost per 1000 parts
Operating Costs	364		303
CPM	22.5		25
Efficiency	0.8		0.8
Part per hour	34,560		38,400
Cost per 1000 Parts	10.55		7.88
In-Line Cost Savings		25%

 

Click here to see the FT 3500 Analysis x2 Roll Fed vs. 1x In-Line FT 8000

 

In-Line System is FT 8000 Roll Fed System is 1 Off Line Extrusion Assembly and 2 X FT 3500 Summary of operating cost/hour (w/o polymer $)
Cost Component	Roll Fed($/HR)		In-Line(S/HR)
Factory Floor Space	22		11
Labor	280		120
Power	150		114
Depreciation	142		127
MRO	30		20
Total	624		392
Cost per 1000 parts
Operating Costs	624		392
CPM	22.5		18
Efficiency	0.8		0.8
Part per hour	69,120		69,120
Cost per 1000 Parts	9.02		5.66
In-Line Cost Savings		37%

Summary of Manufacturing Cost
	$/1000 Parts	Parts/Hour
Large In-Line System	5.66	69K
Large Roll Fed System	7.49	62K
Small In-Line System	7.88	38K
Large Off Line Extrusion System with 2 Small Roll Fed Thermoformers	9.02	69K
Small Roll Fed System	10.55	34K