TL;DR
- Over-application is the most common fault: it costs fluid, hand feel and wash results.
- Weigh the garment before and after spraying to set an actual gram target.
- Consistent pressing after pretreatment matters as much as the spray itself.
Pretreatment is judged visually. Two operators reach 'looks fine' at 22 g and 38 g respectively — a 70% consumable difference on the same garment.
- 1Define a gram target per garment type using a scale, not the eye.
- 2Fix nozzle distance, pressure and pass count; document them per garment class.
- 3Press at a defined time, temperature and pressure to flatten fibres.
- 4Run a wash test monthly and record the result against the gram target.
Standardising the gram target
- Before
- 34 g average, 3.1% rejects
- After
- 24 g average, 1.3% rejects
- 3,000 darks / month, fluid at €0.011 / g
- €330 fluid + €221 reject saving = €551 / month
Interactive example
Loaded labour rate per productive hour
- Loaded rate
- € 26,71 / h
- Labour per garment
- € 0,245
- Annual loaded cost
- € 41.140
Same calculation kernel as the full calculators. For a decision-grade result, open the matching calculator.
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