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Chemical Consumption
Chemical dosage and cost per kg of fabric for any wash process.
Washing Plant
Washing Cost Calculator — Cost per Piece for Garment Washing
Calculate the total washing cost per garment piece, covering labour, chemicals, water, fuel, electricity, and overhead. Essential for accurate FOB pricing and washing plant profitability analysis.
Step By Step
How to Use the Washing Cost Calculator — Cost per Piece for Garment Washing
6 steps
- Enter the daily or batch garment throughput (pieces processed).
- Input your chemical cost per kg and average chemical consumption per piece.
- Add water cost per litre and average water used per piece.
- Enter fuel (gas or diesel) cost and consumption per batch.
- Add total labour cost for the washing department per day.
- Include overhead (depreciation, maintenance, admin) to get the full cost picture.
Worked Example
Worked Example for Washing Cost Calculator — Cost per Piece for Garment Washing
Use this sample to sanity-check your inputs and understand what the final result represents.
- 1Daily throughput: 2,000 pieces
- 2Chemical cost: BDT 1.50/piece
- 3Water cost: BDT 0.80/piece
- 4Fuel/steam cost: BDT 1.20/piece
- 5Labour: BDT 0.60/piece
- 6Overhead: BDT 0.40/piece
Final Result
Total Washing Cost: BDT 4.50 per piece
Methodology
Washing Cost Calculator — Cost per Piece for Garment Washing Formula & Methodology
This section explains the calculation logic, assumptions, and source material used to make the result more trustworthy and easier to verify.
Cost per Piece = Labour Cost/piece + Chemical Cost/piece + Water Cost/piece + Steam/Fuel Cost/piece + Overhead/piece
Labour Cost/piece = Total Daily Labour ÷ Daily Throughput
Chemical Cost/piece = Chemical kg used per piece × Price per kg
Water Cost/piece = Litres per piece × Water rate per litre
Overhead/piece = Monthly Fixed Overhead ÷ Monthly Throughput
Washing Cost Reduction Tips
- 1Track chemical consumption per machine load, not per batch — chemical waste is the single largest controllable cost in most washing plants.
- 2Water recycling through ETP can cut water cost by 20–40%. Factor in ETP capex when calculating the break-even.
- 3Rewash costs are often 3–5× the original washing cost. Track your rewash rate weekly and investigate any week above 3%.
- 4Steam efficiency drops sharply when boiler scale builds up. Clean boiler tubes every 3 months to maintain efficiency.
- 5Compare cost per piece across wash types (normal, enzyme, stone, denim). This helps you price each wash recipe accurately when quoting buyers.
Washing Cost Calculator — Cost per Piece for Garment Washing Frequently Asked Questions
What is the average washing cost per piece in Bangladesh?+
It varies widely by wash type. A simple normal wash costs BDT 3–6 per piece. Enzyme wash runs BDT 5–9. Stone wash and denim finishing can reach BDT 12–25 per piece, largely because of higher chemical and water consumption and the cost of pumice stone.
Which cost component is highest in washing?+
Chemicals and fuel/steam typically make up 50–65% of total washing cost. Labour is a smaller share (15–25%) compared to sewing operations. This is why chemical optimisation and energy efficiency have the highest ROI in washing plant cost reduction.
How do I reduce washing cost without compromising quality?+
The most effective approaches are: optimising chemical dosing (many plants overdose by 15–30%), reducing machine cycle time through recipe improvement, processing full machine loads to reduce per-piece cost of utilities, and recycling rinse water for pre-wash or ETP processes.
Should I include ETP cost in washing cost?+
Yes — ETP (Effluent Treatment Plant) is a legal requirement in Bangladesh and the cost should be allocated per cubic metre of effluent treated, then converted to a per-piece cost. Ignoring ETP cost underprices your washing service and creates a hidden loss.
How does rewash affect total washing cost?+
Every 1% rewash rate adds approximately 1% to your total per-piece cost. At a 5% rewash rate, you're effectively washing 105 pieces to ship 100. If your base cost is BDT 6/piece, a 5% rewash adds BDT 0.30 to the effective cost per shipped piece.