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Calcimator

Paper Recycling Yield Calculator

Calculate usable fiber yield from recycled paper, accounting for moisture, contaminants, deinking losses, and process losses. Includes cost analysis vs. virgin pulp.

About this calculator

Recycled paper feedstock loses weight at every stage between the bale and the finished sheet, and this calculator chains those losses together rather than applying one blanket yield percentage. Starting from feed weight, it first strips out moisture (typically 6-12% of as-received weight), then removes non-fiber contaminants like plastics, staples, and adhesives, then applies a deinking loss for fiber lost during flotation or washing, and finally a process loss covering screening, cleaning, and handling damage — each stage's output feeding proportionally into the next, so the losses compound rather than simply add. The result, usable fiber tons divided by original feed weight, gives you overall yield — real mills typically see 65-90% depending on furnish grade, with old newspapers and mixed office waste at the low end and sorted white ledger or old corrugated containers at the high end.

The calculator also converts your feed cost per ton into an effective cost per ton of usable fiber (which is always higher than the raw feed cost, since you're paying for the rejected material too) and compares that to a fixed $900/ton benchmark for virgin kraft pulp to estimate savings. That virgin-pulp price is a rough midpoint, not a live market quote, so rerun the comparison with your own current kraft price if you need an accurate economic case. The most common input mistake is double-counting moisture inside the contaminant percentage rather than treating them as sequential, independent losses.

Inputs

%
%
%
%

Results

Usable fiber (tons)

7.64

Overall yield (%)76.39
Reject/sludge (tons)2.36
Cost per ton usable ($)$157.09
Total feed cost ($)$1,200.00
Savings vs. virgin ($)$5,674.88
How to Use This Calculator
  1. Enter the feed weight (tons) of incoming recycled paper stock.
  2. Set feed moisture (%) and contaminant percentage (plastics, staples, adhesives).
  3. Input deinking loss (%) and process loss (%) for your mill's specific operation.
  4. Enter the feed cost per ton from your supplier.
  5. Review Usable Fiber (tons), Overall Yield (%), Cost per Ton Usable, and Savings vs. Virgin fiber.

How the result changes with Feed weight (tons)

Feed weight (tons)Usable fiber (tons)
53.82
7.55.73
1511.46
2519.1

What each input means

Feed weight (tons)
Weight of incoming recycled paper feed stock in short tons.
Feed moisture (%)
Moisture content of incoming feed (typically 6-12%).
Contaminants (%)
Non-fiber contaminants: plastics, staples, adhesives, coatings (2-15% typical).
Deinking loss (%)
Fiber lost during deinking by flotation or washing (5-15% typical).
Process loss (%)
Additional screening, cleaning, and handling losses (3-8% typical).
Feed cost ($/ton)
Purchase cost of recycled feed stock per short ton.

What each result means

Usable fiber (tons)
Tons of clean, usable recycled fiber produced.
Overall yield (%)
Percentage of feed weight recovered as usable fiber.
Reject/sludge (tons)
Weight of rejected material and sludge.
Cost per ton usable ($)
Effective cost per ton of usable recycled fiber.
Total feed cost ($)
Total cost of purchasing the recycled feed stock.
Savings vs. virgin ($)
Estimated savings compared to buying virgin kraft pulp at ~$900/ton.

How this is calculated

Worked example, using the default values

  1. Identify Input Parameters
    4 parameters
    Feed weight (tons) = 10, Feed moisture (%) = 8, Contaminants (%) = 5, Deinking loss (%) = 8 = 6 input(s) provided
  2. Calculate Usable fiber
    Usable fiber = afterDeinking * (1 - processLossPct / 100)
    7.639 = 7.639
  3. Calculate Overall yield
    Overall yield = feedWeightTons > 0
    76.39 = 76.39
  4. Calculate Reject/sludge
    Reject/sludge = feedWeightTons - usableFiberTons
    2.361 = 2.361

Engine last updated . Checked against 2 independently-derived tests — how we verify calculators. Built by Paul Gunder, a software engineer, not a licensed financial, medical, or legal professional.

Frequently Asked Questions

Why do the four loss stages compound instead of just adding up?

Each stage's output becomes the starting weight for the next: moisture removal acts on the raw feed weight, contaminant removal acts on the resulting dry weight, deinking loss acts on what's left after contaminants, and process loss acts on what remains after deinking. Because each percentage applies to a progressively smaller base, a 5% contaminant loss and an 8% deinking loss don't simply add to 13% overall loss — the true combined loss is always a bit less than the sum, since later percentages are taken off already-reduced weight.

Is the $900/ton virgin pulp comparison a live market price?

No — it's a fixed reference figure representing a rough midpoint for virgin kraft pulp pricing, not a live quote. The calculator uses it only to estimate savings by comparing your effective cost per ton of usable recycled fiber against that benchmark, so substitute your own current kraft pulp price and recompute manually if you need an accurate economic case.

Why is cost per ton of usable fiber always higher than my feed cost per ton?

Cost per ton usable is your total feed cost divided by usable fiber tons, not by feed weight tons. Since usable fiber tons is always less than feed weight tons because of moisture, contaminant, deinking, and process losses, dividing the same total cost by a smaller number necessarily produces a higher per-ton figure — you're effectively paying for the rejected material too.

What's a realistic overall yield range, and where does my furnish grade typically fall?

Overall yield is usable fiber tons divided by original feed weight, expressed as a percentage. Real mills typically see 65-90% depending on furnish grade: old newspapers and mixed office waste tend toward the low end, while sorted white ledger and old corrugated containers tend toward the high end. Your specific result depends on the moisture, contaminant, deinking, and process loss percentages you enter for your own feedstock.

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