Why TCO Matters More Than Purchase Price
- Purchase price: ~30% of lifetime cost
- Energy consumption: ~25%
- Maintenance & Parts: ~20%
- Unplanned Downtime: ~25%
A "cheap" screen that causes blinding or frequent bearing failures will obliterate capital savings within 18 months through lost production and parts pricing.
5-Year Cost Breakdown (ETE 2260 Example)
| Cost Category | Year 1 | Years 2-5 | Total |
|---|---|---|---|
| Purchase Price | $85,000 | $0 | $85,000 |
| Installation | $12,000 | $0 | $12,000 |
| Energy (45kW) | $28,000 | $112,000 | $140,000 |
| Maintenance | $8,000 | $32,000 | $40,000 |
| Screen Media | $15,000 | $60,000 | $75,000 |
| Downtime Cost | $10,000 | $40,000 | $50,000 |
| Total | $158,000 | $244,000 | $402,000 |
Cost Per Ton Calculation
Assumptions:
- Capacity: 300 t/h
- Operating hours: 4,000/year
- Total tons processed (5 years): 6,000,000 tons
Cost per ton: $402,000 ÷ 6,000,000 = $0.067/ton
Comparison: Horizontal vs Inclined (5-Year TCO)
| Metric | Horizontal (ETE) | Inclined (STE) | Difference |
|---|---|---|---|
| Purchase Price | $85,000 | $72,000 | +18% |
| Energy Cost | $140,000 | $125,000 | +12% |
| Maintenance | $40,000 | $55,000 | -27% |
| Screen Media | $75,000 | $95,000 | -21% |
| Downtime | $50,000 | $85,000 | -41% |
| Total TCO | $402,000 | $447,000 | -10% |
| Cost/Ton | $0.067 | $0.075 | -11% |
Common ROI Scenarios
Scenario 1: Upgrading a Blinding-Prone Setup
- Efficiency gain: 35%
- Additional revenue: $45,000/year
- Payback period: 22 months
Scenario 2: Wet Application Upgrade
- Water reduction: 40%
- Product quality premium: $25,000/year
- Payback period: 18 months