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Washing Cost Calculator
Total washing cost per piece — labour, chemicals, water, fuel, overhead.
CostNest Calculator
Rewash Percentage Calculator — Reject Rate & Cost Impact
Calculate the rewash rejection rate for your washing plant, understand the true cost of every rewash cycle, and identify what it takes to bring your rewash rate under 3%. No account needed — numbers update as you type.
Step By Step
How to Use This Calculator
5 steps
- Enter the total garments loaded into the washing plant in the period.
- Enter the number of garments rejected and sent for rewash.
- Input your base washing cost per piece.
- Add any additional rework cost per rewash (manual work to fix the defect before rewashing).
- The calculator shows rewash % and the total cost added per 100 pieces loaded.
Worked Example
Rewash Rate Example
Use this sample to sanity-check your inputs and understand what the final result represents.
- 1Total Pieces Loaded: 5,000
- 2Pieces Rejected (rewash): 200
- 3Base Wash Cost: BDT 5.50/piece
- 4Rewash rate: 200 ÷ 5,000 × 100 = 4%
Final Result
Rewash Rate: 4% | Extra Cost: BDT 1,100 (200 × BDT 5.50) | Effective cost per shipped piece rises from BDT 5.50 to BDT 5.72
Methodology
Rewash Rate & Cost Formula
This section explains the calculation logic, assumptions, and source material used to make the result more trustworthy and easier to verify.
Rewash Rate (%) = Pieces Rewashed ÷ Total Pieces Loaded × 100
Extra Cost from Rewash = Pieces Rewashed × Washing Cost per Piece
Effective Cost per Shipped Piece = Total Washing Cost ÷ Pieces Actually Shipped
Break-even: if rewash rate drops from 5% to 2%, cost saving = (5%−2%) × Wash Cost × Volume
Practical Guidance
Rewash Rate Reduction Tips
- 1A rewash rate above 5% is a serious process problem. Identify the top 3 defect types causing rewash and address each root cause separately.
- 2Keep a daily rewash log broken down by machine, operator, and defect type. Without data, you're guessing at the cause.
- 3Chemical over-dosage and incorrect temperature are the most common rewash causes for staining and uneven colour. Check your recipe compliance first.
- 4Pre-wash inspection to remove garments with sewing defects before loading saves washing cost on pieces that would fail anyway.
- 5A 1% reduction in rewash rate on 100,000 pieces/month at BDT 6/piece saves BDT 60,000 per month — the ROI on quality training is immediate.
Frequently Asked Questions
What is an acceptable rewash rate for a washing plant?+
Best-in-class washing plants maintain rewash rates below 2%. The industry average in Bangladesh runs 3–6%. A rate above 8% indicates a serious process control problem and needs immediate root cause investigation.
What are the most common causes of rewash?+
The main causes are: chemical staining (over-dosage or wrong chemistry), uneven wash shade (loading variation or liquor ratio inconsistency), fabric damage from excessive agitation or wrong enzyme, and contamination from machine cleanliness issues. Stone wash adds risks from pumice scratching or residue.
How does rewash affect delivery timing?+
Every rewash cycle adds 4–8 hours to the affected garments' lead time. If 10% of an order needs rewash, that's 10% of the order delayed by at least one working day. On tight delivery schedules, high rewash rates are a direct cause of late shipments.
Does rewash damage the garment?+
Yes, each additional wash cycle adds stress to the fabric — additional shrinkage (0.5–1% per rewash), potential colour fading (especially for reactive or vat dyes), and increased wear on seams. Garments with high rewash counts may still fail buyer inspection on dimensional or shade grounds.