Small reductions in pipe overweight can translate into significant annual material savings. Use your own production data to estimate your potential savings, required investment, and payback time.
Potential yearly cost saving
Potential material saving
Overweight
Illustrative example based on 10,000 tonnes annual production
Producing safely within specification is essential. Producing further above specification than necessary is expensive. Across thousands of tonnes of annual pipe production, even a small percentage of overweight can represent a substantial amount of unnecessary material.
A few percentage points of additional material become significant when multiplied across an entire year of production.
Process variation can force production teams to stay further away from the minimum required wall thickness.
Reducing unnecessary material consumption can immediately improve production costs and profitability.
In just a few steps, the calculator translates your actual production figures into an estimate of material savings, investment and payback time.
Enter your production hours, average output, formulation cost, maximum pipe diameter, and current overweight.
Choose which Rollepaal technologies you want to evaluate: Pipe Scanner, Automatic Temperature Centering, and the Rollepaal Gravimetric System.
See your potential yearly cost savings, annual material savings, estimated investment, and expected payback time.
Download your personalized calculation as a PDF for internal evaluation and discussion.
The financial impact of overweight becomes clear when small percentages are multiplied across an entire year of production.
Annual production
Formulation cost
Current overweight
Overweight after optimization
POTENTIAL ANNUAL SAVING
In this example, reducing overweight from 6% to 3% on 10,000 tonnes of annual production represents approximately 300 tonnes of material and €330,000 in potential annual material savings.
CALCULATE MY OWN SAVINGSIllustrative example only. Actual savings depend on your production conditions, product mix, materials and process stability.
The same calculation helps production teams identify improvement potential and gives management the financial information needed to evaluate the opportunity.
PRODUCTION & TECHNICAL LEADERS
Turn current overweight and production data into measurable improvement potential.
✓ Quantify unnecessary material consumption
✓ Compare current and expected overweight
✓ Evaluate different wall thickness control technologies
✓ Build a fact-based improvement case
MANAGEMENT & OWNERSHIP
Translate production efficiency into financial impact and a clearer investment case.
✓ Calculate potential yearly cost savings
✓ Estimate the required investment
✓ Calculate expected payback time
✓ Support CapEx decisions with financial data
Reducing overweight is not about producing below specification. It is about controlling the extrusion process well enough to produce consistently closer to your target.
01 MEASURE
Measure pipe dimensions and wall thickness during production and create the data needed to identify variation and overweight.
02 CENTER
Support more consistent wall thickness distribution by automatically correcting thermal imbalance in the die-head.
03 CONTROL
Control material throughput and pipe weight more accurately to keep production closer to the required target.
04 SAVE
Combine better measurement and process control to reduce unnecessary overweight while continuing to produce within specification.
The calculator lets you evaluate these technologies individually or in combination and estimate what they could mean for your production economics.
Want to understand how these technologies work together?
Read how closed-loop control reduces material loss →
Access the Wall Thickness ROI Calculator and use your own production data to calculate your potential material savings, estimated investment and payback time.
✓ Your own production data
✓ Instant ROI calculation
✓ Downloadable PDF report
Everything you need to know before starting your calculation.
You will need a few basic production figures, including annual production hours, average output, formulation cost, maximum pipe diameter, and your current overweight.
The calculator estimates your potential yearly cost savings, annual material savings, required investment, and expected payback time based on the production data you enter.
You can evaluate the potential contribution of the Pipe Scanner, Automatic Temperature Centering, and the Rollepaal Gravimetric System, individually or in combination.
Yes. After completing the calculation, you can download your results as a PDF for internal evaluation or discussion with colleagues.
No. The calculator provides an indicative estimate based on the information you enter and highlights the potential for material and cost savings on your line. Actual savings depend on factors including product mix, materials, line configuration, process stability, and operating conditions.