BYFUSION°
Platform Cost-to-Operate Proforma
Modular waste-to-infrastructure platform: per-shift, monthly, and annualized cost analysis. Size by module (3-cell / 6-cell / 9-cell / 12-cell) or by target plastic diversion volume. Energy, labor and water apply scale efficiencies as modules are added.
REV 2026.05
Issued
Sources: EIA Tbl 5.6.A (industrial elec, Jun 2026)
EIA Industrial NG (Jan 2026)
§ 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

3-cell is the pilot/entry-level system. Add cells in increments of 3 to scale capacity; a 6-cell can be upgraded by adding another 3-cell module in the field.
SIZED CONFIGURATION6-cell
Number of modules2
Throughput / shift5.3 tons · 480 BB
Annual capacity1,373 tons · 124,800 BB
Annual tons include recommended raw material overstock. ByBlocks reflect estimated production output only.

Equipment 480V 3-PHASE · AUTO-SIZED

01
ByFusion Steam Room Primary electric steam boiler — drives ~80% of system energy. Auto-sized with scale efficiencies.
940kW
02
Shredder 25 HP shredder — standard unit processes up to 1 ton/hr
20.3kW
03
Water Boiler makeup, blowdown, cleaning & sanitary. Scales with module size and shift length.
8.65kgal
Water = base kgal × (cells/6)exp × (hours/8). Below 6 cells, resources scale linearly (per pilot data). At or above 6 cells, the exponent drives economies of scale — 0.643 default 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
Display values are recommended minimum team structure. Update FTE and rates accordingly.

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 · 6-CELL · 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
C · Total Cost to Operate
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

PER-SHIFT COMPARISON
SELECTED FUEL · ELECTRIC BOILER
ALTERNATIVE BOILER FUEL · PER-SHIFT COMPARISON
GAS BOILER
Methodology. Energy = (kW × load × hours) ÷ 1000 → kWh × ¢/kWh. Steam-room kW & water consumption scale with cell count: below 6 cells, resources scale linearly per pilot data; at 6+ cells, an efficiency exponent applies (default 0.643 = ~22% gain per doubling). Shredder kW is fixed at 1 ton/hr capacity. Material handling labor: 3 MH at 3-cell, 4 MH at 6-cell, +1 MH at 9-cell; beyond 9 cells automation flattens labor. QC: 0.5 FTE at 3-cell, 1 FTE at 6+ cells. LDP and Ops FTEs stay constant. Water = base kgal × (cells/6)scale × (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 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.
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