BYFUSION°
Platform Financial Proforma
Cost-to-operate and revenue-impact analysis for the ByFusion modular waste-to-infrastructure platform. Size by module (3-cell / 6-cell / 9-cell / 12-cell) or by target plastic diversion volume. Energy, labor and water apply scale efficiencies; revenue reflects avoided disposal cost, product sales, and equipment/service billing.
§ 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):
PAGE 1 OF 4
§ 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
PAGE 2 OF 4
§ 03
Comparative Analysis
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.
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.
PAGE 3 OF 4
§ 04
Revenue & Diversion Impact
A ton earns twice. Your gate rates, your hauling contract, your residual tonnage. Enter your actuals — reference figures shown on screen for the sales team only.
A · What one ton of residual costs you today $/TON REMOVED
Baling — labor, wire, machine time $10–20/ton all-in
$/ ton
Storage and handling ~$17/ton standing
$/ ton
Freight to disposal $0.125/ton-mi · $6.25 at 50mi
$/ ton
Tipping fee nat'l avg $62.28, +10% YoY
$/ ton
A · Cost removed per ton
$0
B · What one ton produces as ByBlock $/TON PRODUCT
ByBlocks produced per ton auto: 90 blocks/ton
blocks
Value per block ByFusion buyback / local rate
$/ block
B · Product revenue per ton
$0
Line A is market-independent — that cost exists in strong years and weak ones alike, because you were going to bale, haul, and tip that material either way.
C · Material you already handle EXISTING STREAM
Residual in your stream today. You've been paid to collect it, so no service fee applies — the platform removes the disposal cost and turns it into product.
Value per existing ton — A + B
$0
Current tons of residual per month
tons/mo
C · Annual value, existing material
$0
D · New material you can now accept NEW STREAM
Hard-to-recycle plastic you turn away today. New tonnage charged at your diversion rate, on top of product revenue. No avoided disposal cost — it was never yours to dispose of.
Diversion service fee charged per ton
$/ ton
Value per new ton — fee + B
$0
New tons per month
tons/mo
D · Annual material revenue
$0
E · Equipment and service revenue RATE × UNITS · BILLED MONTHLY
New tonnage arrives in containers you place and service.
Covered 40 yd roll-off rental $150–250/mo
$×units
$0
Compactor container rental $220–340/mo
$×units
$0
Swap-out fee $85–190 per swap
$×/ mo
$0
Hauling fee $275–665 per haul, excl. disposal
$×/ mo
$0
Monthly equipment and service revenue
$0
E · Annual equipment and service revenue
$0
TOTAL ANNUAL IMPACT · C + D + E
Annual revenue and cost avoidance
Line A does not depend on any market. It is there in a strong year and a weak one, because you were going to bale, haul and tip that material either way.
$0
Total annual impact
$0
from Section 04
Annual operating cost
$0
from Section 02
Net annual position
$0
impact − opex
Reference figures. Baling $10–20/ton all-in — manpower, energy, wire & maintenance; wire alone $2–4/ton (Recycling Today; Baling Wire Direct). Tipping fee $62.28/ton national average, +10% YoY (EREF). Transfer-trailer haul $275–665, per NWRA regional data.
Note. Section 04 revenue inputs are independent of Section 01 sizing; enter the customer's actual gate rates and tonnage. Net annual position uses the operating cost from Section 02 at the currently selected configuration, state, shift length, and boiler fuel.
Note. Section 04 revenue inputs are independent of Section 01 sizing; enter the customer's actual gate rates and tonnage. Net annual position uses the operating cost from Section 02 at the currently selected configuration, state, shift length, and boiler fuel.
PAGE 4 OF 4