Flake Counter ROI Calculator

Enter your operating assumptions to see an estimate. Improvements are not assumed or guaranteed.

Example values are illustrative assumptions, not guaranteed performance. Loading the example replaces all inputs; adjust them to match your operation.

Volume and baling productivity

Annual bale volume

Baler strokes per minuteSet once. This is held constant while the four current/expected productivity fields are linked.

Current average flakes per bale

Current productive rate (bales/hour)Do not include downtime. Enter either rate or flakes/bale; the paired field is calculated when strokes/minute is entered.

Expected average flakes per bale

Expected productive rate (bales/hour)Enter either rate or flakes/bale; linked calculation uses strokes/minute × 60 ÷ flakes/bale.

Fill in strokes/minute and either the rate or flakes/bale for each case. Editing either paired field recalculates its partner.

Annual stop time

Current plugged baler/breakdown (hours/year)

Expected plugged baler/breakdown (hours/year)

Current stacking-machine stops (hours/year)

Expected stacking-machine stops (hours/year)

Current moisture-check stops (hours/year)

Expected moisture-check stops (hours/year)

Operating costs

Crew labor cost per operating hour (currency)

Fuel volume per productive hourFuel use during downtime is assumed to be zero.

Fuel price per volume (currency)

Total kit investment (currency)

Estimated results

Click Calculate after making changes. Blank inputs will be filled with zero; productive rates must be positive.

Current productive hours—

Expected productive hours—

Annual hours saved—

Annual labor savings—

Annual fuel savings—

Combined annual savings—

First-year net after investment—

First-year ROI—

PaybackNo positive payback at current inputs

Break-even annual bale volumeNot calculable at current inputs

Formulas

Productive hours = annual bales ÷ productive rate. Total time saved = current productive + downtime hours − expected productive + downtime hours.

Labor savings = hours saved × crew cost/hour. Fuel savings = productive hours saved × fuel volume/hour × fuel price/volume; downtime fuel use = zero.

First-year net = combined annual value − investment; ROI = net ÷ investment × 100. Payback only appears for positive annual value.

Results are estimates based on visitor inputs, not guaranteed performance. Fuel volume and fuel price must use matching units. Do not include downtime in productive rates.

Country/region