How to Fill In the Pack Stuff ROI Calculator

​

The calculator helps you see how quickly your new machine will pay for itself and how much you could save each year.

You just need to type numbers into the boxes. The results update automatically.

​

Step 1 – Project Costs
1. Upfront project cost (£)
   This is everything you pay at the start — machine price + delivery + installation/training.

2. Annual running costs (£)
   How much it costs to keep the machine running each year — things like maintenance, spare parts, or ink.

 

Step 2 – Your Work Schedule
3. Working days per year
   How many days a year you use the machine. (Most businesses use around 240 days.)

4. Hours per day
   How many hours a day the machine is in use.

 

Step 3 – Labour Savings
5. Operators reduced (headcount)
   How many staff you won’t need because of the machine. (If none, put 0.)

6. Fully-loaded labour cost (£/hr)
   How much each operator costs per hour, including wages, benefits, and taxes.

 

Step 4 – Output (Production)
7. Units per year (before)
   How many items you produce in a year now (without the machine).

8. Units per year (after)
   How many items you expect to produce in a year with the new machine.

9. Gross margin per unit (£)
   How much profit you make on each unit sold, before overheads.

 

Step 5 – Waste and Outsourcing Savings
10. Baseline scrap rate (%)
    What percentage of products are wasted now.

11. After scrap rate (%)
    What percentage you expect to waste with the new machine.

12. COGS per unit (£) (Cost of Goods Sold)
    How much each unit costs you to make.

13. Outsource saving (£/unit)
    How much you save per unit by not outsourcing production.

 

Step 6 – Read the Results
The bottom section updates live and shows:
- Annual labour savings – How much less you spend on wages.
- Output uplift benefit – Extra profit from making more products.
- Waste reduction benefit – Savings from making less waste.
- Outsourcing savings – Savings from not paying someone else to make products.
- Total annual savings – All the above added together.
- Net annual benefit – Total annual savings minus running costs.
- Payback period – How long it will take for the machine to pay for itself.
- 3-year ROI – How much profit you make over 3 years compared to what you spent.