Fresh Fill Network — Inline vs Pre-Filtered Cost Calculator

Interactive ROI Model · No sign-up

Know the true cost of how you filter.

Enter real production numbers and instantly compare inline vs pre-filtered formats — across capex, labor, scrap, and freight.

Start calculating →

Savings per unit

$—

pre-filtered vs inline

Estimated annual savings

$—

based on inline annual output

Calculator

All results update live as you type. Nothing is sent anywhere.

Your numbers

Adjust each scenario to match your operation.

Line Speed (PPM)pods per minute

Batch Sizeunits per run (MOQ)

Capital Equipment ($)machine purchase cost

Labor Cost ($ / unit)running + changeover labor combined

Scrap Rate (%)steady-state

CO Scrap (units)per changeover

Freight / Truck ($)

Units / Truck

Changeover (hrs)for annual stats only

Capex Life (yrs)

Line Speed (PPM)per machine

No. of Machinescapex shared across all

Batch Sizeunits per run (MOQ)

Changeover (hrs)per machine

Capital Equipment ($)total for all machines (filter welding + filling)

Labor Cost ($ / unit)running + changeover across all machines

Scrap Rate (%)steady-state

CO Scrap (units)per machine per CO

Freight / Truck ($)

Units / Truck

Service Fee ($/unit)supplier fee

Capex Life (yrs)

Annual Run Hourscalendar hrs (24/5 = 6000)

Planned Uptime (%)inline prod hrs ÷ total hrs

Material Cost ($ / unit)full pod value — used to cost scrap

Inline System

$—

total cost per unit

Capex (amortized)—

Labor—

Scrap—

Freight—

Service Fee—

Annual output—

Units / hour—

Changeovers / yr—

Difference

$—

—%

est. annual savings

—

Pre-Filtered

$—

total cost per unit

Capex (amortized)—

Labor—

Scrap—

Freight—

Service Fee—

Annual output—

Units / hour (per machine)—

Changeovers / yr—

Cost driver comparison

Inline (grey) vs pre-filtered (green), each row normalized to the larger value.

How the math works

Formulas match the original economic comparison model exactly.

Annual units (inline)

PPM × 60 × hours × uptime%

Annual units (pre-filtered)

PPM × 60 × hours × uptime% × machines

6 machines run simultaneously

Capex / unit

Total capex ÷ (annual units × life yrs)

Scrap / unit

mat cost × (scrap% + CO scrap ÷ batch)

material cost = full pod value ($0.32)

Labor / unit

Direct input — enter the combined running + changeover labor cost per unit

Freight / unit

freight/truck ÷ units/truck

Know the true cost of how you filter.

Calculator

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