BYFUSION°
Platform Cost-to-Operate Proforma
Modular waste-to-infrastructure platform: per-shift, monthly, and annualized cost analysis. Size by module (Si80 / Li120 / Li240) or by target plastic diversion volume. Energy, labor & water apply scale efficiencies as modules are added.
§ 01
Configuration
Location & Schedule UTILITY RATES BY STATE
Shredder remains electric in both scenarios per system spec.
Platform Sizing SIZE BY MODULE OR BY VOLUME
Si80 is the base 6-head module. Li120 (9-head) and Li240 (18-head) add capacity in larger increments.
SIZED CONFIGURATIONSi80 · 6 head
Number of modules2
Throughput / shift5.3 tons · 480 BB
Annual capacity1,373 tons · 124,800 BB
Equipment 480V 3-PHASE · AUTO-SIZED
01
ByFusion Steam Room
Primary electric steam boiler — drives ~80% of system energy. Auto-sized to match head count with scale efficiencies.
940kW
02
Shredder
25 HP shredder — single unit handles up to 1 ton/hr; no upgrade required for this calculator
20.3kW
03
Water
Boiler makeup, blowdown, cleaning & sanitary. Scales with module size and shift length.
8.65kgal
Water = base kgal × (heads/6)exp × (hours/8). Scale exponent applies only when scaling beyond Si80 (6 heads); at Si80 it has no effect since (6/6)any = 1. Default 0.643 yields ~22% efficiency gain per doubling.
Labor (per shift) FTE × HOURLY × HOURS
RoleFTE × $/hrPer shift
Material handling
×$
$0
LDP operator
×$
$0
Quality control
×$
$0
Ops manager
×$
$0
LABOR / SHIFT$0
Material handlers scale +1 FTE per +3 heads up to Li120; beyond Li120 automation flattens labor. LDP, QC, and Ops FTEs stay constant.
Live Utility Rates SOURCE: EIA · STATE WATER SURVEYS
State
Elec ¢/kWh
Gas $/MCF
Water $/kgal
—
—
—
—
—
—
—
—
—
—
—
—
Override operating state rates for site-specific tariffs (demand charges, contracts):
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§ 02
Cost-to-Operate Proforma
PLATFORM — PER SHIFT OPERATING COST
CALIFORNIA / 12 HR / ELECTRIC
BASIS · 12 HR × 70% LOAD · 250 OP-DAYS / YR
CONFIG · SI80 · 6 HEAD · 5.3 TONS / SHIFT
A · Energy & Utilities
ItemConsumptionCost / shift
ByFusion Steam Room — electric
—
$0
Shredder (electric)
—
$0
Water (boiler makeup, blowdown, cleaning)
—
$0
ENERGY & UTILITIES / SHIFT$0
Energy & utilities / month$0
Energy & utilities / year (annualized)$0
B · Labor
RoleFTE × hrs × $/hrCost / shift
Material handling
—
$0
LDP operator
—
$0
Quality control
—
$0
Ops manager (allocated)
—
$0
LABOR / SHIFT$0
Labor / month$0
Labor / year (annualized)$0
Cost / shift
$0
— per shift
Cost / month
$0
~21 op-days / mo
Cost / year
$0
single-shift basis
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§ 03
Comparative Analysis
Methodology.
Energy = (kW × load × hours) ÷ 1000 → kWh × ¢/kWh.
Steam-room kW & water consumption scale by (heads / 6)0.643; default exponent reflects ~22% efficiency gain per doubling of capacity. Shredder kW is fixed at 1 ton/hr capacity. Material handling labor adds 1 FTE per +3 heads up to Li120; beyond Li120, automation flattens labor; LDP, QC, and Ops FTEs stay constant.
Water = Si80 base kgal × (heads/6)0.643 × (hours/8) × per-state $/kgal.
Gas-boiler equivalent thermal duty = steam-room kW × load × hours × 3,412 BTU/kWh ÷ gas eff., converted at 1,036,000 BTU/MCF.
Disclaimer. This proforma is an estimate for planning purposes only. Geographical, atmospheric, and seasonal conditions affect water source temperatures (impacting boiler makeup heating duty), energy availability, and utility cost structures (demand charges, time-of-use, fuel adjustments, drought surcharges). Labor burden, facility lease, and consumables are not included. Figures are not guaranteed values; actual operating costs will vary.
Disclaimer. This proforma is an estimate for planning purposes only. Geographical, atmospheric, and seasonal conditions affect water source temperatures (impacting boiler makeup heating duty), energy availability, and utility cost structures (demand charges, time-of-use, fuel adjustments, drought surcharges). Labor burden, facility lease, and consumables are not included. Figures are not guaranteed values; actual operating costs will vary.
PAGE 3 OF 3