How can you increase EBITDA in blown film production?

ROLBATCH Executive: EBITDA in film production

A programme for owners, boards, chief operating and financial officers, and managers of blown film production plants. It combines process knowledge with an analysis of costs, margins and EBITDA.

The scope covers production indicators, work organisation, material losses, changeovers and investment assessment. Participants learn how to prepare an action plan using data from their own plant.

Skills developed in the course

• Understand the full cost structure of blown film production and which cost drivers have the greatest impact on EBITDA
• See the link between process parameters and financial performance: how temperature, speed and thickness settings affect margins as well as film quality
• Identify where the plant actually loses money: waste, excessive film thickness, an unstable process, changeover losses and energy consumption, and quantify each of these items
• Recognise when higher output means greater losses: the point at which increasing production volume erodes margins instead of building them
• Assess whether your team's decisions create costs or savings and how standardisation, KPIs and process discipline affect financial performance
• Make investment decisions based on actual ROI, rather than supplier promises
• Develop a 30-day action plan to improve EBITDA using available resources and equipment

Who is this programme for?

• CEOs and business ownerswho are responsible for financial performance and need to understand where profits and losses arise in blown film production
• Board members and investorswho need to assess production efficiency from a financial perspective
• Chief operating officers (COOs) and operations directorswho manage production efficiency across the plant and need to connect operational decisions with financial results
• Chief financial officers (CFOs) and finance directorswho need to understand what drives production costs beyond what standard reports show
• Plant directors and production managerswho want their team to think about profitability as well as keeping the blown film extrusion line running
• Managers entering the plastics industry from other sectors who need to quickly understand how blown film production works and the language used by the production team

Detailed topic coverage

The cost structure of blown film production and its impact on EBITDA A complete breakdown of production costs. Which components dominate. Where the greatest savings potential lies and which cost drivers managers most often underestimate.

Operating margin and process parameters How specific process settings affect margins. Which decisions improve financial performance and which increase costs.

Output and profitability: when producing more means losing more Why increasing line speed or output does not always improve results. Where the break-even point lies and how to recognise it.

Waste as a major source of financial losses How to calculate the true cost of production waste: material value, energy, machine time, labour and lost output. Sample calculations for a given waste percentage on a monthly and annual basis.

Process stability as the foundation of profit How instability translates into costs. The relationship between process repeatability, waste levels and gross margin.

Excessive film thickness and raw material consumption How to calculate additional material consumption when actual thickness exceeds the customer's requirement. Comparing measurements with the specification and assessing the cost of the deviation.

Team management and its impact on financial results How team discipline, knowledge levels and standardised process settings affect production stability and costs.

Selecting and interpreting production indicators Selecting indicators to match the plant's objectives. Interpreting results and using data to plan actions.

Technology investments: how to assess actual ROI How to assess whether a new machine, system or technology will actually pay for itself, and the most common investment mistakes in blown film production.

Case study: the impact of process changes on EBITDA Real examples of optimisation decisions and their measurable impact on financial performance.

Identifying production losses Areas that generate costs in daily production: measuring and costing them, and selecting measures to reduce losses.

Planning waste reduction Assessing organisational and process changes that can be introduced using existing equipment.

Start-up and changeover costs: time and material How to calculate changeover losses and what can realistically be reduced.

Raw material purchase price and total production cost When apparent savings on raw material prices lead to higher total production costs, and how to recognise this before it happens.

A 30-day action plan to improve EBITDA Specific steps your management team can take in the first month using existing resources, machinery and staff.

Programme format

• Practical PDF materials presenting blown film production as a financial system: structured around cost drivers, management decisions and their impact on EBITDA
• Video and audio explanations of selected topics: cost analysis methods, case studies and KPI interpretation
• Final quiz assessing the ability to identify cost drivers and make production decisions based on financial analysis

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.