# Slitter Rewinder Master Roll Trim Waste Calculator

> Source: https://netray.co/tools/slitter-rewinder-master-roll-trim-waste-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Work out how many slit rolls come off a master roll, the edge trim waste and how many masters to pull for a customer order.

## Category

mes-shop-floor

## Industry

Packaging & Converting

## Audience

- Slitter operator
- Production scheduler
- Converting estimator

## Tool

**Kind:** calculator

**Currency:** $

**Inputs:**

#### Master roll width

**Key:** master_w

**Type:** number

**Default:** 60

**Min:** 1

**Step:** 0.25

**Unit:** in

#### Master roll length

**Key:** master_len

**Type:** number

**Default:** 5000

**Min:** 100

**Step:** 100

**Unit:** ft

#### Slit roll width

**Key:** slit_w

**Type:** number

**Default:** 4

**Min:** 0.25

**Step:** 0.125

**Unit:** in

#### Slit roll length

**Key:** slit_len

**Type:** number

**Default:** 1000

**Min:** 10

**Step:** 10

**Unit:** ft

#### Edge trim (each side)

**Key:** edge_trim

**Type:** number

**Default:** 0.25

**Min:** 0

**Step:** 0.0625

**Unit:** in

**Help:** Edge strip removed on each side to get a clean edge.

#### Slit rolls ordered

**Key:** order_rolls

**Type:** number

**Default:** 200

**Min:** 1

**Step:** 10

**Unit:** rolls

#### Material cost

**Key:** price_msf

**Type:** number

**Default:** 12

**Min:** 0

**Step:** 0.25

**Unit:** $ per MSF

**Help:** Dollars per 1,000 square feet of master roll material.

**Outputs:**

#### Slit rolls across the master

**Key:** cuts

**Expr:** max(0, floor((master_w - 2 * edge_trim) / slit_w))

**Format:** integer

**Primary:** true

#### Trim width left over

**Key:** waste_in

**Expr:** master_w - cuts * slit_w

**Format:** decimal

**Description:** Total unusable width per pass in inches, edge trim plus remainder.

#### Trim waste

**Key:** waste_pct

**Expr:** waste_in / master_w * 100

**Format:** percent

**Primary:** true

#### Slit lengths per master

**Key:** lengths

**Expr:** floor(master_len / slit_len)

**Format:** integer

#### Slit rolls per master roll

**Key:** rolls_per_master

**Expr:** cuts * lengths

**Format:** integer

#### Master rolls to pull

**Key:** masters

**Expr:** ceil(order_rolls / max(rolls_per_master, 1))

**Format:** integer

#### Extra slit rolls produced

**Key:** overrun

**Expr:** masters * rolls_per_master - order_rolls

**Format:** integer

**Description:** Rolls beyond the order. Stock them or plan another order to use them.

#### Edge and remainder trim cost

**Key:** trim_cost

**Expr:** masters * waste_in / 12 * master_len / 1000 * price_msf

**Format:** currency

**Chart:**

#### Trim waste percent vs slit width

**Type:** line

**X:** slit_w

**From:** 1

**To:** 20

**Steps:** 39

**Series:**

- waste_pct

**Disclaimer:** Assumes a single slit width per master roll and ignores core, splice and tail waste at the end of each master. Mixed-width cut patterns need a cut-list optimizer.

## Content

**Intro:** Every master roll has a width that rarely divides evenly by the slit width the customer wants. This calculator shows how many slit rolls you get per pass, how much material goes to trim and how many masters to pull for the order.

**Sections:**

#### How to use it

**Body:** Enter the master roll width and length, the slit roll width and length, the edge trim removed on each side and the number of slit rolls ordered. Add the material cost per MSF to see the cost of the trim. The calculator returns slit rolls across, trim width, trim percent, slit rolls per master, masters to pull and the extra rolls you will produce. Use the chart to see how trim percent jumps around as slit width changes and pick widths that sit near the bottom of the curve.

#### Formulas

**Body:** Cuts across equal floor of (master width minus two edge trims) divided by slit width. Trim width equals master width minus cuts times slit width, and trim percent is that divided by master width. Lengths per master equal floor of master length divided by slit roll length. Slit rolls per master equal cuts times lengths, and masters needed equal order rolls divided by that, rounded up. Trim cost is trim width in feet times master length times masters, in MSF, times price.

#### Worked example

**Body:** A 60 inch master with 0.25 inch edge trim and 4 inch slit rolls gives 14 cuts, leaving 4 inches or about 6.7 percent trim. A 5,000 foot master with 1,000 foot slit rolls yields 5 lengths, so 70 rolls per master. An order for 200 rolls needs 3 masters, which produces 10 extra rolls. Those spare rolls are a reason to adjust the order, or to plan a second customer on the same pass.

#### Common mistakes

**Body:** Ignoring the remainder strip is the most common error. It also pays to remember that real slitters lose some length to splices, tails and start-up, and that very narrow rolls may need tighter edge-trim and tension settings. Treat the result as a planning number and check it against your own slitter history.

**Bullets:**

- Confirm minimum and maximum slit widths for the machine
- Include splice and tail allowance for long orders
- Use leftover width for a second customer when possible

**Cta:** If slitting plans are built by hand from open orders, we can help design an on-prem planner that pulls demand and master roll stock straight from the ERP.

**Faq:**

#### What is edge trim in slitting?

**Answer:** Edge trim is the strip removed from each edge of the master roll to leave a clean, uniform edge. It is lost material, so it counts in the trim percent. Typical values range from a fraction of an inch to over an inch depending on product.

#### Why does trim waste jump around with slit width?

**Answer:** Because the number of rolls across must be a whole number. A small change in width can drop one roll off the pass and leave a large remainder. The chart makes these sawtooth steps visible so you can choose better widths.

#### Does this handle mixed slit widths?

**Answer:** No. It assumes one slit width per master. Mixed-width patterns are a cutting-stock problem and need an optimizer, but you can run this tool for each candidate width to build intuition.

#### How is trim cost calculated?

**Answer:** The unused width in feet, multiplied by master length and number of masters, gives trim area. Dividing by 1,000 gives MSF, which is multiplied by the material price per MSF.

## Search terms

slitting yield calculator, master roll slitting calculator, slitter trim waste, how many slit rolls from a master roll, slitting cut list optimization, film slitting waste percent, jumbo roll slitting planner, rewinder planning calculator

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