Savings Estimator
1
Your Line
2
Costs
3
Variation
4
Results
Tell us about your pasting line
We just need a few basics to calculate your annual production volume.
Line Speed
Plates per minute
plt/min
Operating Days Per Year
days
Daily Uptime
What % of a 24hr day does the line run?
%
Plate Height
Average plate dimension
mm
Plate Width
Average plate dimension
mm
What are your costs?
This helps us calculate how much money is at stake.
Lead Oxide Cost
What you pay per kg of paste
$
/kg
Scrap Cost Per Plate
Total cost when a plate gets red-tagged
$
How much does your thickness vary?
This determines how much material gets wasted and how many plates get scrapped. If you're unsure, use the suggested values below each field.
Current Std Dev (Manual)
How much plates vary from target today
mm
Expected Std Dev (With Mate Gauge)
We typically cut variation by 50%
mm
Red Tag Limit
Plates outside this tolerance get scrapped
±mm
Your Mate Gauge MG3 system saves you
—
per year
Year 1 ROI
—
Payback Period
—
5-Year Net Gain
—
Where the savings come from
🧱 Less Material Waste ?When thickness varies a lot, operators over-paste every plate with extra lead oxide to stay safe. We calculate the average over-paste using your standard deviation, multiply by plate area, paste density, and cost per kg. With a Mate Gauge cutting variation in half, you need far less over-paste.
—
🗑 Fewer Scrapped Plates ?Plates outside your red tag limit get scrapped. We use the normal distribution (bell curve) to calculate what percentage of plates fall beyond that limit. Wider variation = more plates in the scrap zone on both sides of the curve.
—
⚙ Indirect Improvements ?Softer savings from automated monitoring: less operator training time, easier OE compliance, fewer downstream jams from inconsistent plates, and better brand value from higher quality. Click to adjust each value. ▾
—
Reduced training time
$
OE compliance demonstration
$
Brand / quality value
$
Less downstream scrap & jams
$
Total Annual Savings
—
What your current variation is costing you today
Wasted Lead Oxide
—
Scrapped Plates
—
The Executive Summary
How The Bell Curve Works
Every plate lands somewhere on this curve. The tighter the curve, the more consistent your plates — and the less money you waste.
Manual control (wider = more variation)
With Mate Gauge (tighter = more consistent)
Red tag zone — plates here get scrapped
Your Pasting Line
Line Speed
plt/min
Operating Days
days
Daily Uptime
%
Plate Height
mm
Plate Width
mm
Costs
Lead Oxide Cost
$/kg
Scrap Cost / Plate
$
Process Variation
Std Dev (Manual)
mm
Std Dev (Mate Gauge)
mm
Red Tag Limit
±mm
1
Your Line
2
Costs
3
Variation
4
Results
Tell us about your pasting line
We just need a few basics to calculate your annual production volume.
Line Speed
Plates per minute
plt/min
Operating Days Per Year
days
Daily Uptime
What % of a 24hr day does the line run?
%
Plate Height
Average plate dimension
mm
Plate Width
Average plate dimension
mm
What are your costs?
This helps us calculate how much money is at stake.
Lead Oxide Cost
What you pay per kg of paste
$
/kg
Scrap Cost Per Plate
Total cost when a plate gets red-tagged
$
How much does your thickness vary?
This determines how much material gets wasted and how many plates get scrapped. If you're unsure, use the suggested values below each field.
Current Std Dev (Manual)
How much plates vary from target today
mm
Expected Std Dev (With Mate Gauge)
We typically cut variation by 50%
mm
Red Tag Limit
Plates outside this tolerance get scrapped
±mm
Your Mate Gauge MG3 system saves you
—
per year
Year 1 ROI
—
Payback Period
—
5-Year Net Gain
—
Where the savings come from
🧱 Less Material Waste ?When thickness varies a lot, operators over-paste every plate with extra lead oxide to stay safe. We calculate the average over-paste using your standard deviation, multiply by plate area, paste density, and cost per kg. With a Mate Gauge cutting variation in half, you need far less over-paste.
—
🗑 Fewer Scrapped Plates ?Plates outside your red tag limit get scrapped. We use the normal distribution (bell curve) to calculate what percentage of plates fall beyond that limit. Wider variation = more plates in the scrap zone on both sides of the curve.
—
⚙ Indirect Improvements ?Softer savings from automated monitoring: less operator training time, easier OE compliance, fewer downstream jams from inconsistent plates, and better brand value from higher quality. Click to adjust each value. ▾
—
Reduced training time
$
OE compliance demonstration
$
Brand / quality value
$
Less downstream scrap & jams
$
Total Annual Savings
—
What your current variation is costing you today
Wasted Lead Oxide
—
Scrapped Plates
—
The Executive Summary
How The Bell Curve Works
Every plate lands somewhere on this curve. The tighter the curve, the more consistent your plates — and the less money you waste.
Manual control (wider = more variation)
With Mate Gauge (tighter = more consistent)
Red tag zone — plates here get scrapped
Your Pasting Line
Line Speed
plt/min
Operating Days
days
Daily Uptime
%
Plate Height
mm
Plate Width
mm
Costs
Lead Oxide Cost
$/kg
Scrap Cost / Plate
$
Process Variation
Std Dev (Manual)
mm
Std Dev (Mate Gauge)
mm
Red Tag Limit
±mm