Cost model

OPEX calculator: the recurring cost of running your line

A quotation tells you what the equipment costs once. This model builds what it costs every year — labour, energy, maintenance, spares and consumables — escalated over your planning horizon, so suppliers can be compared on lifecycle cost, not headline price.

Last reviewed 2026-08-21. Planning model, not an engineering estimate.

Annual operating cost lines

Operating labourOperators, maintenance, supervision — loaded annual costEnergy and utilitiesElectricity, gas, steam, water, refrigerationPlanned maintenanceService contracts, preventive maintenance labourSpare partsAnnual spares consumption after commissioningConsumablesPackaging, lubricants, chemicals, wear partsInsurance and complianceAsset insurance, certifications, auditsOther operating costWaste handling, logistics, QC, IT

Projection and output

Cost escalation (% per year)Projection horizon (years)Annual saleable output (units, tonnes, litres)Optional — enables OPEX per unit

Currency and context

CurrencyDestination country (optional)Sector (optional)

Quick answer

Build the recurring year-1 operating cost of an industrial line or plant — labour, energy, maintenance, spares, consumables, insurance and other lines — and project it forward at a user-entered escalation rate.

Inputs that matter

Operating labour (currency/year)
Energy and utilities (currency/year)
Maintenance (currency/year)
Spare parts (currency/year)
Consumables (currency/year)
Insurance and compliance (currency/year)
Other operating cost (currency/year)
Cost escalation (% per year)
Projection horizon (years)
Annual saleable output (units/year)

How it is calculated

year-1 OPEX = sum of all operating lines; escalated N-year OPEX = year-1 OPEX x Sum((1+e)^(t-1)) for t = 1..N; cost per unit = year-1 OPEX / annual saleable output.

What the result means

Year-1 OPEX
Escalated N-year OPEX — Undiscounted
Average annual OPEX over horizon
OPEX per saleable unit

What is not included

Not an engineering lifecycle study, an energy audit or a reliability model.
Excludes financing cost, depreciation, tax effects and currency risk.
Single-currency model. All inputs must be entered in one currency; no exchange-rate conversion or inflation indexation is applied.
Pre-tax model. Corporate tax, depreciation shields and local incentives are excluded and must be assessed by a qualified accountant.

What must be confirmed

This is a preliminary planning estimate. Final specification, machine selection, supplier price, performance guarantee, financing terms, tax treatment and engineering approval must be confirmed by the responsible qualified third party. Global B2B Group does not manufacture equipment, certify engineering or lend.

Next step

Carry the result into a structured RFQ: Labour and energy assumptions, Maintenance and spares scope, Escalation expectation, Cost per unit target. You review and approve every transferred value — nothing is submitted automatically.

Engine version 1.2.0 · reviewed 2026-08-21 · full methodology

Common questions

What is included in industrial OPEX?

OPEX is the recurring cost of running a line or plant: operating labour, energy and utilities, planned maintenance, spare parts, consumables, insurance and compliance. It excludes the one-off capital cost of buying and installing the equipment, which is CAPEX.

Why does OPEX matter more than the purchase price?

Over a 10–15 year life, operating cost often exceeds the installed CAPEX of a production line. Two quotations with a similar purchase price can differ sharply on energy use, spares consumption and maintenance requirements, so suppliers should be compared on lifecycle cost, not headline price.

Can I carry these figures into an RFQ?

Yes. Use the RFQ button below the results — the operating assumptions are attached to your project brief so shortlisted manufacturers quote against the same duty cycle, utilities and maintenance expectations.