Methodology

How the calculator works

This page documents every formula and every external reference the SupraDye Impact Calculator uses to turn your recipe-level inputs into TCO and ESG figures. The math is auditable; if a brand buyer asks where a number comes from, this page is the answer.

1. Inputs you provide

Every figure on every report is derived from values you (the mill) type into the calculator. Lam Chem does not pre-populate any of your data.

• Batch size (kg of fabric) and fabric blend percentages
• Recipe: reactive dyes, disperse dyes, dyeing auxiliaries, after-treatment auxiliaries — name, dose, and price per kg for each line. Or a flat total recipe cost.
• Liquor ratios for dyeing, soaping, and rinsing baths, plus the number of cycles for each phase — OR a flat total water (L/kg fabric).
• Steam consumption (kg per kg fabric), electricity (kWh per kg fabric), and process time (hours per batch) — entered separately for the conventional process and the SupraDye process.
• Utility rates (cost per m³ fresh water, cost per m³ ETP treatment, cost per ton of steam, cost per kWh electricity).
• Emission factors for steam, grid electricity, water supply, and ETP — sensible UNFCCC AR5 defaults are pre-filled.
• Operating context: batches per day and working days per year (for the annual projection).

2. Total cost of ownership

For each process (conventional and SupraDye), per batch:

recipe_cost = Σ (dye_kg_needed × dye_price_per_kg) + Σ (aux_kg_needed × aux_price_per_kg) utility_cost = water_cost + steam_cost + electricity_cost total_cost = recipe_cost + utility_cost cost_per_kg_fabric = total_cost / batch_size_kg

Dye line cost (reactive or disperse)

Reactive and disperse doses are entered as % owf (on weight of fabric):

dye_kg_needed = batch_size_kg × (dose_pct / 100) dye_cost = dye_kg_needed × dye_price_per_kg

Auxiliary line cost (dyeing and after-treatment)

Auxiliary doses are entered as g/L of the relevant bath:

dye_bath_volume_L = batch_size_kg × dye_liquor_ratio soap_bath_volume_L = batch_size_kg × soap_liquor_ratio dyeAux_kg_needed = dye_bath_volume_L × (dose_g_per_L / 1000) afterAux_kg_needed = soap_bath_volume_L × (dose_g_per_L / 1000)

3. Water and bath volumes

Two input modes. Both produce the same output.

Bath phases mode

water_L = batch_size_kg × ( dye_LR × dye_cycles + soap_LR × soap_cycles + rinse_LR × rinse_cycles )

Total water mode

water_L = batch_size_kg × total_water_L_per_kg

Water cost

water_m3 = water_L / 1000 water_cost = water_m3 × ( fresh_water_per_m3 + etp_per_m3 )

Effluent volume is treated as equal to influent volume — typical for textile dyeing where the bath is fully drained between phases.

4. Steam, electricity, time

steam_kg = batch_size_kg × steam_kg_per_kg_fabric steam_cost = (steam_kg / 1000) × steam_per_ton electricity_kWh = batch_size_kg × elec_kWh_per_kg_fabric electricity_cost = electricity_kWh × elec_per_kWh

Hours per batch is shown for time-saving comparison but does not enter the cost equation directly. If you want to monetise time, factor it into your steam or electricity rate.

5. Greenhouse gas emissions

Emissions follow UNFCCC Assessment Report 5 (AR5) conventions and are attributed across the three GHG Protocol scopes:

• Scope 1 — steam. Direct emissions from on-site combustion at the boiler. The factor (default 0.20 kg CO2e/kg steam) assumes natural-gas-fired boilers at ~85% efficiency. Use a different value for coal- or biomass-fired boilers.
• Scope 2 — grid electricity. Indirect emissions from purchased electricity. Country-specific factors range from ~0.05 kg CO2e/kWh (hydro-heavy grids) to ~0.95 kg CO2e/kWh (coal-heavy grids). The IEA publishes country-level data annually.
• Scope 3 — water supply + effluent treatment. Upstream emissions from fresh water pumping/treatment and downstream emissions from ETP operation. Default values come from IPCC AR5 lifecycle inventory for water utilities and UNFCCC wastewater treatment guidelines (default 0.149 kg/m³ supply, 0.272 kg/m³ ETP).

scope1_ghg = steam_kg × ef_steam scope2_ghg = electricity_kWh × ef_grid scope3_ghg = water_m3 × ( ef_water_supply + ef_etp_treatment ) total_ghg_kg_CO2e = scope1_ghg + scope2_ghg + scope3_ghg

Embedded emissions of dyes and chemicals are NOT included. Lifecycle CO2e of synthetic dyes varies by manufacturer and is typically reported in the supplier's ISO 14040 / ISO 14044 LCA. If your buyers require a cradle-to-gate accounting, this calculator gives you the operational portion; add the supplier-provided embedded portion separately.

6. Annual projection

batches_per_year = batches_per_day × working_days_per_year annual_savings_$ = per_batch_savings_$ × batches_per_year annual_water_saved_L = per_batch_water_saved_L × batches_per_year annual_ghg_avoided_kg = per_batch_ghg_avoided_kg × batches_per_year

Working days defaults to 300 (accounts for weekends and holidays). Mills running 24/7 should use 350. Annual figures assume the same recipe and parameters run year-round; if you change recipes by colour, model each separately.

7. Currency conversion

When you change the displayed currency, the four utility rate fields (fresh water, ETP, steam, electricity) are auto-converted using approximate static FX rates referenced to the US dollar (early 2026 baseline). Recipe prices and the flat-mode total are NOT auto-converted because they are entered per-product and you may transact in different currencies for different products. Adjust manually if needed.

8. Limits and disclaimers

• All figures are estimates based on the inputs you provide. Actual mill performance varies by fabric construction, machine generation, water quality, regional utility tariffs, and grid emission factors.
• The calculator does not include embedded (cradle-to-gate) emissions of dyes and auxiliaries.
• The calculator does not include packaging, transport, or end-of-life emissions.
• The calculator does not constitute a verified ISO 14064 GHG inventory. Use it as a screening / decision-support tool; for compliance reporting, engage a third-party verifier.
• SupraDye performance figures shown alongside the conventional process are projections informed by Lam Chem trial data. Your mill may achieve different results depending on fabric, machinery, and conditions.
• Lam Chem stores your inputs in an encrypted multi-tenant database with row-level security; see the Privacy page for details.

References

• UNFCCC — Methodologies for greenhouse gas inventories (AR5)
• IPCC AR5 — Working Group III, Chapter on industrial processes
• GHG Protocol Corporate Standard — Scope 1, 2, 3 definitions
• IEA — Country-level grid emission factors (annual update)
• ISO 14040 / 14044 — Life cycle assessment principles and framework