Cost&Profit & Energy Consumption Analysis
A beverage line’s financial profile consists of Capital Expenditure (CAPEX) for acquisition and Operational Expenditure (OPEX) for daily running. Optimizing both is key to profitability.
A Simple Financial Plan for Your Beverage Line
Understanding true profitability goes beyond the initial machine price. At MG, we evaluate your entire production ecosystem—from water sourcing to supermarket sales—and provide a clear filling machine manual that helps identify cost drivers, energy consumption points, and operational inefficiencies.
This holistic Cost & Profit Analysis supports data-driven investment decisions, reduces operating expenses, and maximizes long-term returns.
CAPEX – Your Core Investment
This is your initial investment to establish production capability.
| Cost Category | Key Components | MG Insight & Optimization Focus |
|---|---|---|
| Core Production Equipment | Blow Molder, Filler, Capper, Labeler, Packer, Palletizer, Conveyor Systems. | Lifecycle Cost Analysis: We evaluate not just purchase price, but energy efficiency ratings, maintenance costs, and expected lifespan to recommend the most cost-effective solution over 10+ years. |
| Auxiliary & Utilities | Water Treatment Plant, Compressed Air System, Industrial Chiller, CIP System, Boiler. | Right-Sizing: Oversized utilities waste CAPEX and OPEX. We precisely calculate peak demand to specify optimally sized, efficient systems. |
| Installation & Commissioning | Civil Work, Electrical Hook-ups, Piping, Machine Installation, Start-up. | Turnkey Project Management: Our integrated approach prevents cost overruns and delays, ensuring a fixed-price, on-time launch. |
| Spare Parts Initial Stock | Critical wear parts and maintenance kits for the first year. | Strategic Inventory: We help build a cost-effective initial stocklist to minimize early downtime without unnecessary capital tied up. |
OPEX – Ongoing Operating Costs
These recurring costs directly determine your cost per bottle and gross margin.
| Cost Category | Key Drivers & Calculation Basis | MG Optimization Strategy |
|---|---|---|
| Raw Materials & Inputs | PET Preforms/Resin, Bottle Caps, Labels, Shrink Film, Corrugated Cartons. Cost = Consumption per bottle × unit price. | Yield Optimization: High-accuracy filling and low-scrap blowing directly reduce material waste. We target >99.5% material yield. |
| Energy Consumption | Electricity, Steam, Compressed Air. Cost = Power (kW) × Runtime × Energy Rate. | Integrated Energy Analysis: Our core focus. We analyze and minimize energy at each stage (see detailed breakdown below). |
| Water & Effluent | Process Water, CIP/SIP Water, Cooling Water, Sewage Costs. Cost = Volume (m³) × (Water Rate + Sewage Rate). | Closed-Loop Systems: We advocate for water recovery in rinsers and cooling loops, reducing intake and effluent by up to 40%. |
| Labor | Operators, Technicians, Supervisors. Cost = Number of FTE × Fully Burdened Wage. | Automation Level Design: We right-size automation to reduce direct labor, focusing personnel on supervision and value-added tasks. |
| Maintenance & Repairs | Preventive Maintenance Kits, Unplanned Repairs, Service Contracts. | Predictive Maintenance: Using data to shift from costly reactive repairs to planned, lower-cost interventions, extending part life. |
| Quality & Compliance | Laboratory Testing, Certification Audits, Sanitation Chemicals. | Built-in Compliance: Equipment designed for easy cleaning and validation reduces long-term chemical and labor costs for QA. |
Energy Costs – Your Biggest Controllable Expense
Energy is typically the second-largest OPEX after raw materials. Here’s a stage-by-stage breakdown for a standard PET water line:
| Production Stage | Primary Energy Consumers | Typical % of Line’s Total Energy Use | MG Efficiency Solutions |
|---|---|---|---|
| Blow Molding | • Heating Lamps (Infrared) • High-Pressure Air Compressor • Hydraulic System | ~35-45% | • Servo-Driven Hydraulics: Cuts electricity by 30-40%. • IR Heater Reflectors & Zoning: Reduces heating power by 15%. • Heat Recovery: Captures lamp heat for pre-heating compressed air. |
| Filling & Capping | • Conveyor Motors • CIP System (Heating Water) • Air Compressor (Pneumatics) | ~20-25% | • High-Efficiency Motors & VFDs on conveyors. • Heat Exchangers in CIP to recover heat from returning fluid. • Low-Pressure Pneumatic Design minimizes compressor load. |
| Labeling & Packaging | • Shrink Tunnel (Heating Elements) • Packer & Palletizer Servos/Pneumatics | ~15-20% | • Insulated Shrink Tunnels with focused heat zones. • Servo-Electric Drives replacing pneumatic cylinders where possible. |
| Utilities (Plant-Wide) | • Water Chillers • Central Air Compressor • Lighting, HVAC | ~20-25% | • Centralized & Smart Utility Control: Systems that modulate output based on real-time line demand, preventing idle waste. |
Key Metric: Cost per Bottle (Energy):(Total Line Power in kW × Operating Hours × $/kWh) / Total Bottles Produced
Example: A 24,000 BPH line using 400 kW at $0.10/kWh has an energy cost of $0.00167 per bottle. A 15% efficiency gain saves $25,000+ annually.
The MG Value: Delivering a Lower Cost Per Bottle
We don’t just sell machines — we help you lower your total cost to own and run them.
Upfront Cost Modeling
Get a clear cost & profit forecast with your quote, so you know the numbers before you invest.Built for Efficiency
Energy-saving design comes standard, not as an extra.OPEX Tracking After Start-Up
We help you compare real operating costs vs. projections and find ways to optimize further.
Want to see the real cost behind your production line?
we’re here to all your questions
Can we handle maintenance ourselves?
Yes. Tier 1 tasks are covered by Online Academy training. Tier 2/3 services should be done by MG technicians.
How does predictive maintenance work?
The iCare Gateway collects PLC and sensor data and analyzes trends. Alerts are sent before failures occur.
What if a critical part fails under a plan?
Tier 2/3 plans cover labor. Parts are discounted and shipped with priority.
How do we start a maintenance assessment?
Request a free remote assessment. We review your line and provide recommendations within one week.
Is certification provided?
Yes. A downloadable MG Certificate is issued after passing each module quiz.
A Filling Solution That Doubles Efficiency
— Proven by 100+ Factories
Tell us your product, and we’ll match you with the most suitable filling solution.
