Reducing costs while maintaining or improving quality is a common cry heard in the electrocoat industry. Electro-coaters are required to provide a high quality product at an ever-reducing cost. Reducing costs can be tricky or impossible if the right information is not known. A hidden cost might be missed or an area with a higher return could be overlooked. Originally this paper was going to cover all the costs associated with an electrocoat system and how to calculate them. The scope of such a work is too large for a single paper. It was decided, for this paper, to present some basic formulas and methods for calculating costs and applying them to an electrocoat system. The formulas and methods used in this paper are for estimation purposes; actual costs could vary. Mathematical formulas discussed in this paper pertain mainly to energy consumption and paint usage, which are some of the major costs associated with operating an electrocoat system. Examples of how each formula might be used are discussed.
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