The model. Powder sprayed per day = 42 lb/hr × trigger hours × guns. Savings = the value of powder that lands on the part instead of the floor when transfer efficiency rises from a worn gun’s 50% to a maintained gun’s 60%: sprayed × 10% × price × days.

The fixed figures. A single manual gun runs a typical 50–70% TE; output of 300 g/min ≈ 42 lb/hr is a common manual rate. The 10-point gain is what proper maintenance and fresh wear parts recover versus a worn, neglected gun. Guns, hours, price and days you set yourself.

First-pass framing. These figures value first-pass transfer. If you run reclaim, some over-sprayed powder comes back — but reclaim isn’t free or perfect: fines are lost, and it adds labor, contamination risk and color-change cost. Higher first-pass TE reduces all of that too.

Estimate for planning only — actual results depend on part geometry, powder chemistry, booth and setup.