ROI Calculator for Inline Gas Measurement | Sparklike Laser Integrated

Estimate your current QC costs

Fill in the grey fields. Calculated values update automatically.

1 — Basic information

Working days per year

days

Labour cost per hour

€ / h

2 — Time used for manual gas assurance

Hours per dayStaff time spent on manual measurement

h / day

Labour cost per day

—

Labour cost per year

—

3 — Extra cost for special IGU samples

Sample cost per unitDestructive or special test cost

€

Units tested per day

units

Sampling cost per day

—

Sampling cost per year

—

4 — Any other additional costs

Additional daily overheadEquipment, gases, consumables for QC

€ / day

Overhead cost per year

—

Total annual QC cost

Monthly equivalent: —

—

Warranty claims & defect costs

Optional

Don't know these numbers yet? No problem — skip this step and get your ROI from QC savings alone. Fill it in when you have the data to see the full picture.

The hidden iceberg. A defective IGU that passes undetected with manual spot-checks costs far more than the unit itself — field replacement, technician travel, delayed projects, and brand damage. With only 1–5% sampling, most low-fill units ship undetected. Inline 100% measurement with Sparklike Laser Integrated stops them at the line.

Production volume

IGU units produced per dayCapacity when the line is running

units

Production days per yearMay differ from QC staff working days in Step 1

days

Line downtimePlanned maintenance, changeovers, breakdowns

—

Effective production days / year

—

Annual production volume

—

Defect & warranty parameters

How to read these fields Think of your production in two stages: units caught at the line (rework/scrap) and units that slip through to customers (warranty claims). Enter your best estimates — even rough numbers reveal significant hidden costs.

How many IGUs fail gas-fill spec? Your estimated defect or low-fill rate as a % of all units produced. Industry typical range: 0.5–3%. If unsure, start with 1.5%.

Cost to fix or scrap one defective unit at the line What it costs internally when a low-fill IGU is caught before shipping — labour to rework, replacement glass, disposal. Typical range: €40–€150.

€

How many defective units reach the customer? Of all defective units, what % slip through QC and are shipped? With manual 1–5% spot-checking, most do. Typical range: 10–40%.

Total cost of one field warranty claim Everything it costs when a customer reports a failed IGU: technician visit, travel, replacement unit, admin, and the goodwill damage. Typical range: €150–€500.

€

How well does inline 100% measurement catch defects? The % of defective units that Sparklike Laser Integrated detects and flags before they leave the line. Typical performance: 90–99%.

Annual impact — without Sparklike

Defective units per year

—

Rework / scrap cost per year

—

Warranty claims cost per year

—

Total defect + warranty exposure / year

—

Savings with Sparklike inline measurement

Rework savings per year

—

Warranty claim savings per year

—

Total defect & warranty savings / year

—

Device investment & gas savings

Enter the Sparklike Laser Integrated investment to calculate your payback period.

Sparklike Laser Integrated investment

Device investment (capex)Contact Sparklike for a site-specific quote

€

Annual maintenance & support

€ / yr

Argon gas optimisation savings

Gas / argon fill cost per unit Based on European argon market price (~€0.62/kg): a 1m×1m IGU with 16mm gap needs ~16 litres = ~0.03 kg argon ≈ €0.02 per unit. Check with your gas supplier for your actual cost.

€

Fill optimisation improvementReduction in over-fill waste with live feedback

Gas savings per year

—

Total annual savings (all categories)

QC labour + sampling + defects + warranty + gas

—

Your ROI summary

Based on your inputs — here is the full financial case for Sparklike Laser Integrated.

Conservative estimate — QC cost savings only (Step 1)

Payback on QC savings alone (vs. 3-year target) —

01 year2 years3 years

Full picture — including warranty & defect savings (Steps 1–3)

These savings are real but harder to predict exactly — use as additional justification, not the primary ROI argument.

Annual savings breakdown

QC savings only (conservative) Full savings incl. warranty & defects Total investment

Ready to eliminate your QC cost?

Get a site-specific quote and see Sparklike Laser Integrated in action on your production line.

Sparklike Laser Integrated ROI calculator

Use the ROI calculator below to put a number on what you currently spend on manual gas check — and what silent defects may be costing you.

How much is manual gas QC
costing your line?

Estimate your current QC costs

Warranty claims & defect costs

Device investment & gas savings

Your ROI summary

Ready to eliminate your QC cost?

Products

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Sparklike Laser Integrated ROI calculator

Use the ROI calculator below to put a number on what you currently spend on manual gas check — and what silent defects may be costing you.

How much is manual gas QCcosting your line?

Estimate your current QC costs

Warranty claims & defect costs

Device investment & gas savings

Your ROI summary

Ready to eliminate your QC cost?

Products

How much is manual gas QC
costing your line?