Investment Justification Tool
Calculate Your Return.
Justify the Investment.
Select the INNOSEN products you are evaluating, enter your actual production numbers, add your own risk estimates, and see your payback period in real time.
All fields pre-filled with defaults — adjust to your numbers
Calculated hard benefit
Hard cost payback
With your risk estimate
Select products to evaluate — click to toggle
Inline Production Sensors
Innosen Trinity — Feature Comparison
Currency for all prices
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USD
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⬆
Select one or more products above
Choose the INNOSEN products you are evaluating to see their ROI calculator.
Inline · Sheet Feeding
IS231 Double Sheet Detector
Self-adjusting — no manual calibration. Eliminates mis-detection risk and speeds every changeover.
Enter your quoted price
✏ Enter the INNOSEN quoted price to calculate payback
Production ParametersAdjust to your numbers
shifts
per shift
How many times per shift is the line reset for a new job, coil, or format?
days
mins
IS231 self-adjusts at each changeover — no manual calibration needed. How many minutes does manual calibration currently take?
$/hr
Total cost of running the line per hour — labour, energy, overhead. Used to value changeover time saved.
Double-Sheet Event CostAdjust to your numbers
events
How many times per year does a double sheet reach the press undetected — causing a jam, die damage, or scrap batch?
mins
How long does it take to clear the jam, inspect, and restart the press?
USD
Repair or replacement cost for tooling damaged by a double sheet. Enter 0 if not applicable.
USD
Cost of sheets and press consumables scrapped per event.
Your Risk Estimates — OptionalAdjust to your numbers
USD
What would one double-sheet can reaching a filler or customer cost your business?
USD
Per event — leave at 0 if not applicable.
events/yr
Calculated BenefitsAdjust to your numbers
Changeover time saved / year—
Line cost recovered from changeover saving—
Press downtime cost avoided—
Tooling & scrap cost avoided—
Your risk estimate (annual)—
ROI Summary — IS231
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Sheet Feeding
IS416 Sheet Skew Measurement System
Detects skewed sheets early on lacquering and welding lines. Prevents roll damage, sheet losses, and unplanned downtime.
Enter your quoted price
✏ Enter the INNOSEN quoted price to calculate payback
Lacquering Line — Skew & Sheet LossesAdjust to your numbers
USD
Material + lacquer cost per sheet. Used to value sheets lost before IS416 detects the skew.
events
How many times per month does skew occur on the lacquering line?
sheets
Without IS416, how many sheets are typically scrapped before an operator notices skew?
/yr
Major events caused by severe undetected skew — broken feedback chain component, jam, or roll crash. Enter 0 if this has not happened.
sheets
Welding Line — Downtime & Roll DamageAdjust to your numbers
$/hr
Total cost of running the line per hour — labour, energy, overhead. Used to value downtime events.
/mo
Wire breaks attributable to skewed sheet — not all wire breaks qualify.
mins
/mo
How often do rolls need re-profiling due to skew-induced uneven wear?
mins
/yr
USD
Your Risk Estimates — OptionalAdjust to your numbers
USD
Skewed cans reaching a customer or triggering a recall.
USD
Non-conformance, corrective action, or lost contract value.
events/yr
Calculated BenefitsAdjust to your numbers
Sheet scrap avoided — early skew detection—
Sheet scrap avoided — calamity prevention—
Welder rethread downtime avoided—
Roll re-profiling downtime avoided—
Roll replacement cost avoided—
Your risk estimate (annual)—
ROI Summary — IS416
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Welding Line
IS610 Plain Margin Inspector
Inspects the plain margin and detects weld wire issues. Prevents leaking cans, roll damage, and unplanned downtime.
USD
Welding Line Parameters
$/hr
/mo
mins
/mo
mins
/yr
USD
Your Risk Estimates — Optional
USD
Leaking cans at filler, in distribution, or at customer.
USD
events/yr
Calculated Benefits
Re-threading downtime avoided—
Re-profiling downtime avoided—
Roll replacement cost avoided—
Your risk estimate (annual)—
ROI Summary — IS610
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Lacquering Line
IS651 Missing Lacquer Detector
Detects sheets with missing or partial lacquer before the press. Prevents corrosion, tooling damage, and customer complaints.
USD
Production Parameters
sheets/hr
hrs
days
Quality Risk Parameters
sheets
USD
USD
USD
Your Risk Estimates — Optional
USD
Corrosion reaching end consumer or triggering a recall.
USD
events/yr
Calculated Benefits
Total sheets / year—
Corrosion cost avoided—
Tooling damage avoided—
Customer complaint cost avoided—
Your risk estimate (annual)—
ROI Summary — IS651
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Conversion Press
IS240 Tab Verifier
Detects double shells and missing tabs on the conversion press. Minimises expensive downtime — quick calibration, modular, no adjustment needed for aluminium or steel.
USD
Press Production Parameters
strokes/min
lanes
IS240 handles up to 4 lanes on one controller.
hrs
days
USD
Defect & Downtime Parameters
events/mo
mins
$/hr
events/yr
USD
mins
IS240 recalibrates in seconds — no tolerance adjustment needed.
stops/mo
Your Risk Estimates — Optional
USD
Ends without tabs causing filler line issues or customer returns.
events/yr
Calculated Benefits
Downtime cost avoided—
Tooling damage cost avoided—
Faster calibration savings—
Your risk estimate (annual)—
ROI Summary — IS240
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Coil / Cut-to-Length Line
IS1261 On-line Sheet Length Measurement
±0.1mm accuracy at 9,000 sheets/hr. Tighter cutting saves material; prevents short sheets causing weld overlap and clipped curls downstream.
USD
Coil Line Parameters
sheets/hr
hrs
days
USD/sheet
mm
mm
Operators cut long to avoid short-sheet rejects without IS1261.
mm
Downstream Reject Savings
sheets/mo
USD
%
Your Risk Estimates — Optional
USD
Short sheets causing weld issues or clipped curls reaching a customer.
events/yr
Calculated Benefits
Total sheets / year—
Annual material cost savings—
Downstream reject savings—
Your risk estimate (annual)—
ROI Summary — IS1261
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Measurement Tool · UV Curing
IS310 UV Logger
Monitors UV lamp power and energy in the curing oven. Enables data-driven lamp replacement and catches under-cure before defective sheets reach the press.
USD
UV Lamp Maintenance
ovens
lamps
USD
times/yr
%
IS310 data shows exactly when replacement is actually needed.
USD
Under-Cure Defect Parameters
events/yr
sheets
USD
mins
$/hr
Your Risk Estimates — Optional
USD
Under-cured cans failing decoration quality in field.
events/yr
Calculated Benefits
Lamp replacements avoided / year—
Lamp & labour savings—
Scrap sheets avoided / year—
Scrap cost avoided—
Downtime cost avoided—
Your risk estimate (annual)—
ROI Summary — IS310
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
QA Lab Instrument · Enamel Rating
IS9015 Can Stand for Enamel Rater
Versatile, durable can stand covering the widest range of can sizes. Carbide contacts need no can preparation. Self-checking contacts on every test.
USD
QA Lab Parameters
cans/day
days
mins/test
No sanding or can prep needed with carbide contacts.
$/hr
events/yr
IS9015 self-checks contacts on every single test.
USD
USD/yr
Your Risk Estimates — Optional
USD
A false pass reaching the filler or end consumer.
USD
events/yr
Calculated Benefits
Total tests / year—
Labour savings (faster testing)—
False pass cost avoided—
Maintenance cost avoided—
Your risk estimate (annual)—
ROI Summary — IS9015
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
QA Lab Instrument · Enamel Rating
IS9020TMR End Adapter for Enamel Rater
Tests coating porosity on ends, caps, sheets, cones, domes, and rivets. Self-checking contacts every test, automatic voltage compensation, magnetic top plates for rapid size changes.
USD
QA Lab Parameters
ends/day
days
mins/test
$/hr
changes/day
Magnetic plates swap in seconds vs. minutes with manual adapters.
mins
events/yr
Bad contacts are the #1 cause of unreliable end adapter readings.
USD
USD/yr
Your Risk Estimates — Optional
USD
False pass reaching filler, distribution, or end consumer.
USD
events/yr
Calculated Benefits
Total ends tested / year—
Labour savings (testing + plate changes)—
False pass cost avoided—
Maintenance cost avoided—
Your risk estimate (annual)—
ROI Summary — IS9020TMR
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Welder Discharge
IS625 Inverted Can Label Detector
Detects upside-down and inside-out can bodies on the welder discharge — before cans are seamed. Prevents internal coating ending up on the outside and wrong-side seaming. Self-calibrating, no controller needed.
Enter your quoted price
✏ Enter the INNOSEN quoted price to calculate payback
Production ParametersAdjust to your numbers
cans/min
Welder discharge speed.
hrs
days
$/can
Defect Event ParametersAdjust to your numbers
events/mo
Number of batches per month where orientation errors occur without IS625.
cans
Wrong-orientation cans reaching seamer or filler before detection.
USD
Labour and line interruption to sort and remove bad cans.
events/yr
USD
Quarantine, re-inspection, customer notification.
Your Risk Estimates — OptionalAdjust to your numbers
USD
Inverted cans reaching filler, causing fill-side coating exposure or label orientation failures at the customer.
USD
events/yr
Calculated BenefitsAdjust to your numbers
Can body scrap cost avoided—
Rework & sorting cost avoided—
HFI cost avoided—
Your risk estimate (annual)—
ROI Summary — IS625
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
Inline · Welder Discharge
IS670 Missing Side Seam Lacquer Detector
Detects missing or gapped lacquer on the external side seam of 3pc cans — before the curing oven. Prevents corrosion, leakage, and customer complaints from unlacquered seams reaching the market. Self-calibrating, no controller needed.
Enter your quoted price
✏ Enter the INNOSEN quoted price to calculate payback
Production ParametersAdjust to your numbers
cans/min
Welder discharge speed.
hrs
days
$/can
Cost of a can body that must be scrapped due to unlacquered seam.
Defect Event ParametersAdjust to your numbers
events/mo
Batches per month where side seam lacquer is absent or gapped.
cans
Cans with unlacquered seam passing through before detection.
USD
Labour and line interruption to identify and remove affected cans.
incidents/yr
Leaking or corroded cans reaching filler or distribution.
USD
Filler downtime, line cleaning, product loss, customer debit.
Your Risk Estimates — OptionalAdjust to your numbers
USD
Corrosion or leakage discovered at the filler or in the field.
USD
events/yr
Calculated BenefitsAdjust to your numbers
Can scrap cost avoided—
Rework & sorting cost avoided—
Leakage / corrosion incident cost avoided—
Your risk estimate (annual)—
ROI Summary — IS670
Payback — Hard Costs
—
days
Enter product cost above
Payback — With Your Risk
—
days
Enter risk estimates
Annual (Hard)
—
hard costs/yr
Annual (With Risk)
—
incl. your risk
3-Yr Net (Hard)
—
after investment
3-Yr Net (With Risk)
—
after investment
Hard costs ROI (3yr)progress
With risk estimates (3yr)progress
Day 0Yr 1Yr 2Yr 3
QA Lab Instrument · Coating Thickness
IS860 CoatPro — Coating Thickness Gauge
IP65-rated capacitance-based coating thickness gauge with <1% non-linearity. Easy onsite annual calibration — no lab shipment, gauge always available. Integrates with IS1100 Innolytix® Software for full measurement intelligence.
⚡ Capability Comparison — IS860 CoatPro vs Old Generation Gauge
IS860 CoatPro vs Old Generation Coating Thickness Gauges. Both measure coating weight by capacitance. The difference is resolution, what the gauge does for the operator — and what happens to every measurement afterwards.
| Feature | IS860 CoatPro | Old Generation Gauge |
|---|---|---|
| Measurement Accuracy & Reliability | ||
| Measurement principle Gauge Technology used to detect coating weight |
Capacitance | Capacitance |
| Electronics non-linearity Gauge Error introduced by the IS860 electronics unit alone |
<1% — higher resolution & stability | Typically >1% |
| Display resolution Gauge Finest reading increment shown on the IS860 screen |
2 decimal places — reveals trends earlier | 1 decimal place typical |
| Measurement repeatability System Combined result of gauge electronics, probe condition, calibration quality and measurement setup |
High — standardised per test | Operator-dependent |
| On-device statistics Gauge Mean, min, max, standard deviation shown per session on the IS860 display |
✓ | — |
| Instrument Design & Durability | ||
| IP65 protection rating Gauge Fully sealed against dust and water spray — IS860 housing rated IP65 |
✓ | — |
| Housing Gauge IS860 body construction material and durability |
IP65 powder-coated stainless steel | Plastic / basic enclosure |
| Display & interface Gauge How the operator interacts with the IS860 unit |
7" full-colour touchscreen + jog wheel — glove-friendly | Small display, single control |
| Multilanguage interface Gauge Menu language selectable on the IS860 unit |
✓ | — Single language |
| Onboard data storage Gauge Readings stored on the IS860 without PC connection |
10,000 readings — 10× more than previous-gen | Limited / none |
| Connectivity & Integration | ||
| Connectivity options Gauge How the IS860 connects to factory systems and IS1100 Innolytix® software |
Dual: RS485 + Ethernet | Proprietary / RS485 only |
| Probe range Probe Sample types reachable via Innosen probes — Hoverprobe® II (flat sheets), Tube Probe IS9561 (tubes), Aerosol Probe IS9571 (formed cans & aerosols) |
Full Innosen probe range — flat sheets, cans, tubes, aerosols | Limited fixture range |
| Calibration & Service | ||
| Annual calibration process Gauge What is required to keep the IS860 calibrated each year |
✓ Onsite — using Innosen calibration box. No shipment, zero downtime | — Return to lab / manufacturer |
| Gauge availability during calibration Gauge Whether production can continue during the annual calibration |
Always available — calibrated on your floor | Gauge unavailable — weeks offsite |
| Extended warranty Gauge Manufacturer warranty option on the IS860 unit |
✓ 5-year extended warranty option | Standard only |
| Data & Intelligence — with IS1100 Innolytix® Software | ||
| Automatic measurement recording Every result saved to a central database without operator action |
✓ Automatic via IS1100Software | — Manual log or spreadsheet |
| Batch / operator / line tagging Results automatically linked to product, operator and line |
✓ Automatic via IS1100Software | — Manual entry or none |
| Coating weight trend charts Visual history of readings across batches, shifts and time periods |
✓ Live via IS1100Software | — Not available |
| Coating distribution maps Visualise where coating weight varies across a sheet or batch |
✓ Via IS1100Software | — Not available |
| Statistical process control (SPC) Control charts, Cp, Cpk, out-of-control alerts |
✓ Via IS1100Software | — Not available |
| Instant batch retrieval Find any historical measurement by batch, date or operator in seconds |
✓ Instant search via IS1100Software | — Manual file search |
| Multi-line / multi-site dashboard Centralised view across all gauges, lines and facilities |
✓ Via IS1100Software | — Not available |
| Customer audit-ready reports One-click export of formatted QA evidence |
✓ Via IS1100Software | — Manual compilation |
Capability source:
GaugeIS860/IS810 electronics unit
ProbeInnosen probe or fixture
SystemCombined gauge + probe/fixture
SoftwareIS1100 Innolytix®
IS860 CoatPro capabilities shown with IS1100 Innolytix® Software integration. ✓ IS1100 rows require IS1100 Innolytix® Software. Contact INNOSEN for a full technical review of your setup.
QA Lab Instrument · Enamel Rating
IS810 EnamelPro — Enamel Rater
EN 15384-1/-2 compliant enamel rater with self-checking contacts. Delivers a reliable, unambiguous pass/fail on every test. Integrates with IS1100 Innolytix® Software for full traceability and trend analysis.
⚡ Capability Comparison — IS810 EnamelPro vs Old Generation Gauge
IS810 EnamelPro vs Old Generation Enamel Raters. All use reverse-voltage technology. The difference is contact reliability, compliance, what the instrument does for the operator — and what happens to every result afterwards.
| Feature | IS810 EnamelPro | Old Generation Gauge |
|---|---|---|
| Measurement Method & Reliability | ||
| Measurement method Gauge Technology used to assess enamel integrity |
Reverse-voltage (ERV) | Reverse-voltage (ERV) |
| EN 15384-1/-2 compliance Gauge Compliance verified by the IS810 electronics — adjustable 2–30 V output meets standard requirements |
EN 15384-1/-2 compliant | Functional standard |
| Self-checking contacts Gauge Built into the IS810 — automatically verifies probe contact and electrolyte level before every test |
✓ Automatic | — Manual check required |
| Reliable pass/fail result Gauge IS810 electronics deliver an unambiguous reading — enamel defects appear physically on the can during reverse-voltage testing |
Clear, unambiguous pass/fail | Operator interpretation |
| Test repeatability Gauge + Fixture Driven by IS810 contact verification (gauge) and consistent sample positioning via IS9015 Can Stand or other Innosen fixture |
High — verified contact per test | Contact-dependent / variable |
| False pass rate Gauge IS810 pre-measurement contact check eliminates unreliable readings before they are recorded |
Significantly reduced | Higher risk |
| Instrument Design & Workflow | ||
| Manual preparation per test Gauge IS810 self-checking routine runs automatically — no manual contact verification needed |
Self-checking — ready immediately | Manual contact check + setup |
| On-device statistics Gauge Pass rate, mean, test count shown per session on the IS810 display |
✓ | — |
| Multiple test configurations Gauge + Fixture Test type selected on the IS810 gauge; each configuration (inner, outer, ends, tubes etc.) uses the appropriate Innosen fixture or adapter |
Configurable onboard | Limited / fixed |
| Connectivity options Gauge How the IS810 connects to factory systems and IS1100 Innolytix® software |
Triple: USB-C + RS485 + Ethernet | Proprietary / RS485 only |
| Onboard data storage Gauge Readings stored on the IS810 without PC connection |
100,000 readings — 100× more than competing gauges | Limited / none |
| Calibration & Service | ||
| Annual calibration process What is required to keep the gauge calibrated each year |
✓ Onsite — using Innosen calibration box. No shipment, zero downtime | — Return to lab / manufacturer |
| Gauge availability during calibration Gauge Whether production testing can continue during annual calibration of the IS810 |
Always available — calibrated on your floor | Gauge unavailable — weeks offsite |
| Extended warranty Gauge Manufacturer warranty option on the IS860 unit |
✓ 5-year extended warranty option | Standard only |
| Data & Intelligence — with IS1100 Innolytix® Software | ||
| Automatic result recording Every pass/fail result saved to central database without manual entry |
✓ Automatic via IS1100Software | — Manual log or paper |
| Batch / operator / line tagging Results linked to product, operator and production line automatically |
✓ Automatic via IS1100Software | — Manual entry or none |
| Enamel pass-rate trend charts Track pass rates over time — see if enamel quality is drifting before failures occur |
✓ Live via IS1100Software | — Not available |
| Statistical process control (SPC) Control charts and out-of-control alerts for enamel pass rates |
✓ Via IS1100Software | — Not available |
| Instant batch retrieval Retrieve any historical enamel result by batch, date or operator in seconds |
✓ Instant search via IS1100Software | — Manual file search |
| Audit-ready QA reports One-click export of enamel rating history for customer or regulatory audit |
✓ Via IS1100Software | — Manual compilation |
| Multi-line / multi-site dashboard Centralised enamel QA view across all instruments and facilities |
✓ Via IS1100Software | — Not available |
Capability source:
GaugeIS860/IS810 electronics unit
ProbeInnosen probe or fixture
SystemCombined gauge + probe/fixture
SoftwareIS1100 Innolytix®
IS810 EnamelPro capabilities shown with IS1100 Innolytix® Software integration. ✓ IS1100 rows require IS1100 Innolytix® Software. Contact INNOSEN for a full technical review of your setup.
Combined Investment Summary
| Product | Type | Investment | Annual (Hard) | Payback (Hard) | Annual (With Risk) | Payback (With Risk) | 3-Yr Net (Hard) |
|---|
💡
Two payback figures explained: Hard Costs payback uses only measurable, defensible numbers — downtime, material, maintenance, and avoidable defect costs. With Your Risk adds your own estimates for brand damage, recalls, and compliance exposure. Your risk estimates are your own assessment, clearly shown separately. The hard cost ROI already makes a compelling case on its own — your risk estimates show the full picture.
INNOSEN — innovative sensors for canmaking
Hard cost figures are calculated from your inputs. Risk estimates are your own assessment shown separately. Actual results depend on production conditions.
Hard cost figures are calculated from your inputs. Risk estimates are your own assessment shown separately. Actual results depend on production conditions.