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+ 1 (844) 466-7763

Email

sales@ionrectifiers.com

Rectifiers Made in the USA

ION ROI Estimator

Anodizing Pulse Rectifier ROI Calculator

Use your operating information to estimate recurring operating value, simple purchase payback, and lease-to-own cash flow from higher rectifier efficiency, programmable ramping, improved throughput, and more repeatable process control.

Sample values are preloaded. Replace them with your own operating data. Study results and sample assumptions are not guarantees; your actual results will depend on alloy, chemistry, temperature, part geometry, racking, waveform, target thickness, and available production demand.

Enter your operating information

Your results update automatically as you change the values. Dollar amounts are in U.S. dollars.

Live calculation
Your calculator entries are not saved. This calculator processes the values in your browser and does not submit, transmit, store, or save them. If you refresh, close, or leave this page, the calculator returns to the sample defaults. External links open in a new tab so your current calculation can remain open.
1

Equipment and financing

Enter the rectifier price and other project costs you are evaluating. You can also compare lease-to-own financing with a direct purchase.

$

Enter the rectifier price from your quote before separately stated freight, installation, or other capital costs.

$

Enter the freight, installation, and other capitalized startup costs you expect to pay.

Financing option
%

Percentage of the rectifier price you would pay at closing.

%

Used only if you do not enter a quoted monthly payment.

months

Number of monthly payments in the financing agreement you are evaluating.

%

Your end-of-term purchase option or residual value as a percentage of the rectifier price.

$/mo

Enter the monthly payment from a lender or leasing quote you have received. Leave this at zero to estimate a payment from APR, term, down payment, and buyout.

$

One-time documentation or financing fees you expect to pay at closing.

2

Production and throughput

Enter your accepted, billable loads and contribution margin—not gross selling price—to avoid overstating the value of added capacity.

days

Number of days per year your tank or line normally operates.

loads

Enter your average number of good, accepted, billable loads—not the number of loads started.

min

Enter your average time under power for a representative hard-coat load.

min

Use a conservative target until it has been verified on your alloy, bath, racking, coating thickness, and acceptance criteria.

min

Enter your average non-anodize time for loading, unloading, rinsing, and transfers that a faster waveform normally will not reduce.

%

Enter 0% if you cannot sell more production. Use a higher value only when your backlog, outsourcing, or capacity constraints support it.

$/load

Enter your selling price for one additional load minus the labor, chemistry, utilities, packaging, and other variable costs required to produce it.

3

Electrical energy and efficiency

Use measured complete-cycle kWh per accepted load when you have it. Otherwise, use your voltage, current, cycle time, and efficiency data for a planning estimate.

Existing process
V DC

Enter your representative cycle-average voltage, not only the final or maximum voltage.

A DC

Enter the representative current for your load, not merely the rectifier nameplate rating.

%

Use this to account for ramping and time below the entered current. Enter 100% if your current entry is already a complete-cycle average.

%

Replace the sample with your measured AC-input-versus-DC-output efficiency or a reliable manufacturer value.

Proposed ION process
V DC

Enter the cycle-average operating voltage you expect, not the rectifier’s maximum voltage rating.

A DC

Enter the load current you expect after increasing ASF or changing the process—not simply the rectifier nameplate rating.

%

Use this to account for your programmed ramp, pulse duty cycle, and time below the entered current. Enter 100% if the current is already cycle-averaged.

%

Enter the efficiency stated in your ION quote or project-specific technical specification.

Why the values are separate: Your higher-ASF pulse process may use more current or a different average voltage even while reducing cycle time. Entering both operating points helps prevent the calculator from overstating your electrical savings. Measured AC kWh per accepted load remains the preferred validation method.

Utility cost and possible energy-efficiency incentive
$/kWh

Enter your blended electricity rate. Put separately verified demand-charge savings under other operating savings.

4

Quality, labor, cooling, and uptime

Enter only the recurring benefits you can support with your current costs and conservative improvement assumptions.

$/yr

Enter your annual cost for stripping, reprocessing, scrap, added labor, chemistry, and lost line capacity.

%

Use a modest percentage until improved repeatability has been demonstrated on your production loads.

min/load

Estimate the operator time you may save through stored recipes, automatic ramping, timers, amp-hour control, and reduced manual intervention.

$/hr

Enter your fully burdened hourly labor cost, including wage, payroll burden, and benefits.

$/yr

Enter the annual value of avoided repairs, emergency service, rental equipment, and documented contribution margin lost during rectifier downtime.

$/yr

Enter only cooling or chiller savings that are not already included in your facility-level kWh comparison.

$/yr

Enter only additive or consumable savings you can verify for your hard-coat process.

$/yr

Enter other verified savings such as demand-charge reduction, avoided outsourcing, reduced setup or documentation labor, or avoided expedited freight.

5

Optional tax benefits

Tax benefits are shown separately from recurring operating savings. Include them only after you understand the assumptions and plan to confirm eligibility with your tax adviser.

Five-year model setting
%/yr

Keep this at 0% for a conservative model. Increase it only if rising energy rates, pricing, or contribution margin are part of your documented forecast.

Your results update automatically. Use the button to jump directly to your summary after editing the inputs.

Your estimated business case

Your recurring operating benefits are shown separately from one-time tax and incentive benefits.

Updated now
Annual recurring operating benefit $0 Energy, throughput, quality, labor, uptime, cooling, and other recurring savings.
Simple purchase payback after modeled one-time benefits — Uses a simple payback calculation; timing of incentives and taxes may differ.
Estimated lease monthly net cash flow $0 Monthly operating benefit less modeled lease payment, before one-time tax benefits.
Five-year purchase ROI 0.0% Five-year cumulative purchase net cash benefit divided by equipment and startup outlay.

Annual recurring benefit breakdown

Shows which of your assumptions drive the operating case.

Total annual operating benefit$0

Five-year cumulative cash flow

Full-realization scenario. One-time modeled benefits are added in Year 1. Financing obligations after Month 60 are excluded.

Direct purchase Lease-to-own

Operating metrics

  • Current energy per load0 kWh
  • Proposed energy per load0 kWh
  • Energy change per load0.0%
  • Current accepted loads per year0
  • Added saleable loads per year0
  • Theoretical capacity change0.0%

One-time modeled benefits

  • Bonus-depreciation tax value$0
  • Potential R&D credit$0
  • State/utility incentive$0
  • Total purchase one-time benefit$0
  • Five-year purchase net benefit$0
  • Five-year lease net benefit$0

Lease-to-own metrics

  • Calculated or quoted payment$0/mo
  • Monthly operating benefit$0
  • Monthly net operating cash flow$0
  • Benefit-to-payment coverage0.00×
  • Upfront lease cash requirement$0
  • Cumulative lease cash turns positive—
Conservative realization sensitivity: 50%, 75%, and 100%
Metric50% realization75% realization100% realization
Annual recurring operating benefit$0$0$0
Purchase payback after modeled one-time benefits———
Lease monthly net operating cash flow$0$0$0
Lease benefit-to-payment coverage0.00×0.00×0.00×
Important disclosure: This calculator is a planning tool, not a guarantee of process performance, financing approval, tax treatment, or incentive eligibility. Validate energy and production assumptions on your representative loads. Have your qualified tax adviser review all tax figures, and obtain an actual lender or leasing quote for financing terms. Do not count the same savings in more than one field. Privacy: The calculator processes your entries only in your browser and does not transmit or save them.
IRS: first-year depreciation IRS: research-credit instructions