Methodology

How the worksheet is calculated

Updated 2026-10-17.

PlantBench is a free, neutral equipment ROI worksheet for fruit and vegetable processors. It estimates labor savings, yield recovery, energy cost, simple payback, and an undiscounted five-year net from the plant inputs on the sheet. The figures are estimates for a capex discussion, not a quote, a design, or a guarantee. The site is from VegTech Systems and is independent of any single OEM.

Formulas

Annual pounds = weekly pounds × weeks per year. When volume is entered as an annual total, annual pounds are that figure.
Operating days = days per week × weeks per year.
Annual labor hours = person-hours per shift × shifts per day × operating days.
Loaded wage = base wage × (1 + burden percent / 100), rounded to the cent.
Labor dollars = annual labor hours × (labor reduction percent / 100) × loaded wage. Labor reduction is capped at 100%.
Yield pounds = annual pounds × (applied yield points / 100). Applied yield points are the lesser of the entered points and the current loss.
Yield dollars = yield pounds × product value per pound, rounded to the cent.
Energy dollars = (current kWh − projected kWh) × electricity price + (current therms − projected therms) × gas price per therm. A negative result is an added cost.
Annual savings = labor dollars + yield dollars + energy dollars.
Payback years = capital divided by annual savings. Payback is omitted when capital is missing or annual savings are not positive.
Simple ROI (percent) = annual savings divided by capital × 100.
Five-year net = five years of annual savings minus capital. There is no discount rate.

Plant defaults

These are the starting values when no state is selected. A selected state replaces the wage, electricity price, and gas price only.

Input	Default	Source
Volume basis	weekly	Worksheet assumption, not a published series.
Production	100,000 lb per week	Worksheet assumption, not a published series.
Weeks per year	48	Worksheet assumption, not a published series. The seasonal toggle uses 35 weeks. The year-round toggle uses 50 weeks.
Shifts per day	2	Worksheet assumption, not a published series.
Days per week	5	Worksheet assumption, not a published series.
Wage	$19.50 per hour	Planning rate used when no state is selected. Not the BLS OEWS May 2025 national mean of $24.81 (OEUN000000000000051000003).
Burden	32%	Load factor 1.32, the same factor applied to a selected state's BLS base wage. Loaded wage on this default is $25.74.
Product value	$0.55 per lb	Worksheet assumption, not a published series.
Electricity price	$0.085 per kWh	Planning rate used when no state is selected. Not the EIA 2025 U.S. industrial average of 8.62 cents per kWh.
Gas price	$0.95 per therm	Planning rate used when no state is selected. Not the EIA 2025 U.S. industrial price of $5.23 per Mcf divided by 10.37.

State rates

Electricity, when a state is selected: U.S. Energy Information Administration, electricity/retail-sales annual industrial price (sectorid IND), 2025, cents per kilowatthour. The U.S. total is 8.62 cents per kWh. Every state row in this file has a published industrial price.
Natural gas, when a state is selected: U.S. Energy Information Administration, Natural Gas Industrial Price, annual, dollars per thousand cubic feet (N3035xx3), 2025. The U.S. series N3035US3 is $5.23 per Mcf. Dollars per therm = dollars per Mcf / 10.37. 18 states use the U.S. gas average because EIA left the cell blank.
Labor, when a state is selected: U.S. Bureau of Labor Statistics, Occupational Employment and Wage Statistics, May 2025 hourly mean wage, Production Occupations (SOC 51-0000), all industries. The national series OEUN000000000000051000003 is $24.81 per hour. Loaded cost is the base wage × 1.32. Every state row in this file has a published wage.
With no state selected, the worksheet uses a planning wage of $19.50 per hour, electricity at $0.085 per kWh, and gas at $0.95 per therm. Those three rates are not the BLS May 2025 national mean and not the EIA 2025 national industrial averages.
Equipment capital, person-hours, labor-reduction percent, current loss, yield points, and kilowatt-hour and therm intensities are worksheet assumptions. They are not a published series and they are not a vendor quote.

Calculators

Each calculator uses the formulas above. The equipment defaults below are the starting point on that page. The worked example is the calculator output for those defaults with no state selected.

Peeler ROI calculator

Estimate labor, peel loss, steam or electricity, and payback for a vegetable peeler before the capex meeting.

Mid-size vegetable peeler. Steam-leaning energy, a few points of peel loss recovered.

Input	Default	Source
Capital	$185,000.00	Worksheet assumption, not a published series.
Person-hours per shift	32	Worksheet assumption, not a published series.
Labor reduction	40%	Worksheet assumption, not a published series.
Current loss	14%	Worksheet assumption, not a published series.
Yield improvement	3 points	Worksheet assumption, not a published series.
Current electricity	8 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	18 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	1.6 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	4.5 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 32 person-hours/shift × 2 shifts × 240 days = 15,360.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 15,360 hours × 40% × $25.74 = $158,146.56.
Yield dollars: 4,800,000 lb × 3 points × $0.55/lb = $79,200.00.
Electricity: (38,400 − 86,400) kWh × $0.085 = -$4,080.00.
Gas: (7,680 − 21,600) therms × $0.95 = -$13,224.00.
Energy dollars: -$4,080.00 + -$13,224.00 = -$17,304.00.
Annual savings: $158,146.56 + $79,200.00 + -$17,304.00 = $220,042.56.
Payback: $185,000.00 divided by $220,042.56 = 10 months.
Simple ROI: $220,042.56 divided by $185,000.00 × 100 = 119%.
Five-year net: 5 × $220,042.56 minus $185,000.00 = $915,212.80.

Freezer and IQF ROI calculator

See whether an IQF or blast freezer pays back on labor and grade after the kilowatt-hours are counted.

Fluidized IQF planning load, about 0.17 kWh per pound. Labor savings are modest on purpose.

Input	Default	Source
Capital	$950,000.00	Worksheet assumption, not a published series.
Person-hours per shift	16	Worksheet assumption, not a published series.
Labor reduction	18%	Worksheet assumption, not a published series.
Current loss	7%	Worksheet assumption, not a published series.
Yield improvement	2 points	Worksheet assumption, not a published series.
Current electricity	25 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	170 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 16 person-hours/shift × 2 shifts × 240 days = 7,680.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 7,680 hours × 18% × $25.74 = $35,582.98.
Yield dollars: 4,800,000 lb × 2 points × $0.55/lb = $52,800.00.
Electricity: (120,000 − 816,000) kWh × $0.085 = -$59,160.00.
Gas: (0 − 0) therms × $0.95 = $0.00.
Energy dollars: -$59,160.00 + $0.00 = -$59,160.00.
Annual savings: $35,582.98 + $52,800.00 + -$59,160.00 = $29,222.98.
Payback: $950,000.00 divided by $29,222.98 = 32.5 years.
Simple ROI: $29,222.98 divided by $950,000.00 × 100 = 3%.
Five-year net: 5 × $29,222.98 minus $950,000.00 = -$803,885.10.

Dehydrator ROI calculator

Labor, gas, and recovered pounds for a vegetable dehydrator. The yield field is not water loss.

Hot-air vegetable dryer. Yield means recovered saleable pounds, not water driven off.

Input	Default	Source
Capital	$320,000.00	Worksheet assumption, not a published series.
Person-hours per shift	20	Worksheet assumption, not a published series.
Labor reduction	22%	Worksheet assumption, not a published series.
Current loss	12%	Worksheet assumption, not a published series.
Yield improvement	3.5 points	Worksheet assumption, not a published series.
Current electricity	12 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	35 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	2 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	14 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 20 person-hours/shift × 2 shifts × 240 days = 9,600.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 9,600 hours × 22% × $25.74 = $54,362.88.
Yield dollars: 4,800,000 lb × 3.5 points × $0.55/lb = $92,400.00.
Electricity: (57,600 − 168,000) kWh × $0.085 = -$9,384.00.
Gas: (9,600 − 67,200) therms × $0.95 = -$54,720.00.
Energy dollars: -$9,384.00 + -$54,720.00 = -$64,104.00.
Annual savings: $54,362.88 + $92,400.00 + -$64,104.00 = $82,658.88.
Payback: $320,000.00 divided by $82,658.88 = 3.9 years.
Simple ROI: $82,658.88 divided by $320,000.00 × 100 = 26%.
Five-year net: 5 × $82,658.88 minus $320,000.00 = $93,294.40.

Blancher ROI calculator

Estimate steam, yield, and labor for a vegetable blancher. Overblanching is a yield loss, not a free quality upgrade.

A specified blancher often uses more steam than a casual tank. Labor savings stay small.

Input	Default	Source
Capital	$140,000.00	Worksheet assumption, not a published series.
Person-hours per shift	12	Worksheet assumption, not a published series.
Labor reduction	15%	Worksheet assumption, not a published series.
Current loss	6%	Worksheet assumption, not a published series.
Yield improvement	1 points	Worksheet assumption, not a published series.
Current electricity	5 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	8 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	3 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	7 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 12 person-hours/shift × 2 shifts × 240 days = 5,760.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 5,760 hours × 15% × $25.74 = $22,239.36.
Yield dollars: 4,800,000 lb × 1 points × $0.55/lb = $26,400.00.
Electricity: (24,000 − 38,400) kWh × $0.085 = -$1,224.00.
Gas: (14,400 − 33,600) therms × $0.95 = -$18,240.00.
Energy dollars: -$1,224.00 + -$18,240.00 = -$19,464.00.
Annual savings: $22,239.36 + $26,400.00 + -$19,464.00 = $29,175.36.
Payback: $140,000.00 divided by $29,175.36 = 4.8 years.
Simple ROI: $29,175.36 divided by $140,000.00 × 100 = 21%.
Five-year net: 5 × $29,175.36 minus $140,000.00 = $5,876.80.

Washer ROI calculator

Labor and cull-rate math for a vegetable washer. Water and wastewater are called out because the model does not price them.

Labor is the main washer story. Water and wastewater are not priced in the model.

Input	Default	Source
Capital	$75,000.00	Worksheet assumption, not a published series.
Person-hours per shift	16	Worksheet assumption, not a published series.
Labor reduction	30%	Worksheet assumption, not a published series.
Current loss	5%	Worksheet assumption, not a published series.
Yield improvement	0.8 points	Worksheet assumption, not a published series.
Current electricity	8 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	12 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 16 person-hours/shift × 2 shifts × 240 days = 7,680.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 7,680 hours × 30% × $25.74 = $59,304.96.
Yield dollars: 4,800,000 lb × 0.8 points × $0.55/lb = $21,120.00.
Electricity: (38,400 − 57,600) kWh × $0.085 = -$1,632.00.
Gas: (0 − 0) therms × $0.95 = $0.00.
Energy dollars: -$1,632.00 + $0.00 = -$1,632.00.
Annual savings: $59,304.96 + $21,120.00 + -$1,632.00 = $78,792.96.
Payback: $75,000.00 divided by $78,792.96 = 11 months.
Simple ROI: $78,792.96 divided by $75,000.00 × 100 = 105%.
Five-year net: 5 × $78,792.96 minus $75,000.00 = $318,964.80.

Optical sorter ROI calculator

Labor versus air, cameras, and yield for an optical sorter on a vegetable line.

Inspection-belt labor, cut hard. Yield assumes you currently throw good product away.

Input	Default	Source
Capital	$240,000.00	Worksheet assumption, not a published series.
Person-hours per shift	40	Worksheet assumption, not a published series.
Labor reduction	50%	Worksheet assumption, not a published series.
Current loss	8%	Worksheet assumption, not a published series.
Yield improvement	1.5 points	Worksheet assumption, not a published series.
Current electricity	3 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	9 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 40 person-hours/shift × 2 shifts × 240 days = 19,200.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 19,200 hours × 50% × $25.74 = $247,104.00.
Yield dollars: 4,800,000 lb × 1.5 points × $0.55/lb = $39,600.00.
Electricity: (14,400 − 43,200) kWh × $0.085 = -$2,448.00.
Gas: (0 − 0) therms × $0.95 = $0.00.
Energy dollars: -$2,448.00 + $0.00 = -$2,448.00.
Annual savings: $247,104.00 + $39,600.00 + -$2,448.00 = $284,256.00.
Payback: $240,000.00 divided by $284,256.00 = 10 months.
Simple ROI: $284,256.00 divided by $240,000.00 × 100 = 118%.
Five-year net: 5 × $284,256.00 minus $240,000.00 = $1,181,280.00.

Full-line ROI calculator

One worksheet for a complete vegetable processing line, with wide error bars and a clear view of which term dominates.

A stack of soft assumptions. Use it to see which term dominates, then price the machines one by one.

Input	Default	Source
Capital	$1,800,000.00	Worksheet assumption, not a published series.
Person-hours per shift	80	Worksheet assumption, not a published series.
Labor reduction	45%	Worksheet assumption, not a published series.
Current loss	16%	Worksheet assumption, not a published series.
Yield improvement	4.5 points	Worksheet assumption, not a published series.
Current electricity	40 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	150 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	4 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	12 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 80 person-hours/shift × 2 shifts × 240 days = 38,400.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 38,400 hours × 45% × $25.74 = $444,787.20.
Yield dollars: 4,800,000 lb × 4.5 points × $0.55/lb = $118,800.00.
Electricity: (192,000 − 720,000) kWh × $0.085 = -$44,880.00.
Gas: (19,200 − 57,600) therms × $0.95 = -$36,480.00.
Energy dollars: -$44,880.00 + -$36,480.00 = -$81,360.00.
Annual savings: $444,787.20 + $118,800.00 + -$81,360.00 = $482,227.20.
Payback: $1,800,000.00 divided by $482,227.20 = 3.7 years.
Simple ROI: $482,227.20 divided by $1,800,000.00 × 100 = 27%.
Five-year net: 5 × $482,227.20 minus $1,800,000.00 = $611,136.00.

Robotics and automation ROI calculator

Labor, yield, and a modest energy term for robotics, automation cells, and full lines in a fruit or vegetable plant.

Labor is usually the largest term. Yield and quality gains depend on the application. Energy is often modest compared with labor savings.

Input	Default	Source
Capital	$450,000.00	Worksheet assumption, not a published series.
Person-hours per shift	28	Worksheet assumption, not a published series.
Labor reduction	45%	Worksheet assumption, not a published series.
Current loss	8%	Worksheet assumption, not a published series.
Yield improvement	1 points	Worksheet assumption, not a published series.
Current electricity	4 kWh per 1,000 lb	Worksheet assumption, not a published series.
Projected electricity	10 kWh per 1,000 lb	Worksheet assumption, not a published series.
Current gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.
Projected gas	0 therms per 1,000 lb	Worksheet assumption, not a published series.

Annual throughput: 100,000 lb/week × 48 weeks = 4,800,000 lb.
Operating days: 5 days/week × 48 weeks = 240.
Labor hours: 28 person-hours/shift × 2 shifts × 240 days = 13,440.
Loaded wage: $19.50 × (1 + 32%) = $25.74.
Labor dollars: 13,440 hours × 45% × $25.74 = $155,675.52.
Yield dollars: 4,800,000 lb × 1 points × $0.55/lb = $26,400.00.
Electricity: (19,200 − 48,000) kWh × $0.085 = -$2,448.00.
Gas: (0 − 0) therms × $0.95 = $0.00.
Energy dollars: -$2,448.00 + $0.00 = -$2,448.00.
Annual savings: $155,675.52 + $26,400.00 + -$2,448.00 = $179,627.52.
Payback: $450,000.00 divided by $179,627.52 = 2.5 years.
Simple ROI: $179,627.52 divided by $450,000.00 × 100 = 40%.
Five-year net: 5 × $179,627.52 minus $450,000.00 = $448,137.60.

Excluded

These figures are rough estimates for discussion, not a quote, bid, or engineering study. Defaults are industry-style assumptions and will not match your plant until you edit them. The model ignores maintenance, installation, freight, water, wastewater, depreciation, taxes, incentives, and the time value of money. Yield math treats improvement as extra saleable pounds of input weight, which is the wrong model for some drying and grading decisions. Confirm every assumption before a capex meeting.

Water and wastewater.
Product quality and grade, except where they appear as recovered saleable pounds.
Line capacity, downtime, and changeover.
Maintenance.
Installation and freight.
Depreciation, taxes, and incentives.
Financing and the time value of money. The five-year net has no discount rate.

Sensitivity

The sensitivity table scales only labor reduction percent and yield improvement points. Energy, capital, and every other input stay as entered.

Conservative multiplies those two inputs by 0.5. Base multiplies them by 1. Aggressive multiplies them by 1.5.

Before the worksheet is calculated, labor reduction is capped at 100% and yield points are capped at the current loss.

The table is labeled: Sensitivity only — edit the main inputs for a full recalculation.