Stop Losing Money to Sensor Repositioning Sensor Repositioning Lack of Insight Edge Drift Lack of Data Material Scrap Improper Guiding Legacy Sensors Unplanned Stops Hydraulic Systems Pneumatic Systems

Without real-time width measurement, deviations go undetected until material is already scrapped or downgraded. It is difficult for operators to notice even 25mm of width change on a 2.5m wide roll, and impractical to measure wound rolls manually due to safety hazards. Manual spot-checks miss events between measurements, excessive trim goes undetected, and customer rejections come as costly surprises. Select your application type below — each has unique cost drivers.

Sources: PFFC Industry Benchmarks, FTA Flexographic Standards, TAPPI Converting Guidelines

Pneumatic and hydraulic actuators carry hidden operational costs that electric actuators eliminate entirely. Compressed air is the most expensive utility in a manufacturing plant — with overall system efficiency as low as 10–15% (DOE). Hydraulic systems waste up to 60% of input energy running pumps continuously, add oil spill liability, and require costly servo valve calibration. Select your actuator type below to calculate the true annual cost.

Sources: U.S. DOE Compressed Air Challenge, British Fluid Power Association, Tolomatic TCO Study, Machinery Lubrication, OSHA Safety Data, Liberty Mutual Workplace Safety Index

Legacy web handling systems from discontinued product lines bleed money in ways that don’t show up on a single line item. Obsolete parts carry 150%+ markups on the secondary market. Technicians waste hours searching for discontinued components. Inventory carrying costs run 20–30% of stock value annually — and much of that inventory may never be used. Each year of deferral increases the eventual retrofit cost through rush engineering and unplanned downtime. Meanwhile, aging equipment is the #1 cause of unplanned downtime (42–50% of all incidents), and retiring workers take irreplaceable tribal knowledge with them. This calculator quantifies the hidden cost categories so you can see the true annual premium of “just keeping it running.”