Decontamination Shower Systems Running Costs: $766K Monthly Fixed

Decontamination Shower Systems Running Costs

Total annual revenue for Decontamination Shower Systems in 2026 is projected at $1442 million, generating an EBITDA of $8868 million Your operational foundation requires a fixed monthly overhead of approximately $76,600, covering key salaries and facility leases

7 Operational Expenses to Run Decontamination Shower Systems

#	Operating Expense	Expense Category	Description	Min Monthly Amount	Max Monthly Amount
1	Facility Lease	Fixed Overhead	The monthly lease for the manufacturing facility is a fixed $18,500, requiring strict utilization metrics like revenue per square foot	$18,500	$18,500
2	Core Payroll	Fixed Overhead	Initial core payroll is about $42,333 per month, covering 5 key FTEs like the General Manager and Lead Design Engineer	$42,333	$42,333
3	Sales Commissions	Variable Cost	Sales commissions start at 45% of revenue in 2026, acting as a major variable cost that scales directly with the $12 million average monthly revenue	$0	$5,400,000
4	Liability Insurance	Fixed Overhead	Given the hazardous environment usage, product liability insurance is a critical fixed cost of $4,200 per month	$4,200	$4,200
5	Shipping/Logistics	Variable Cost	Shipping and logistics represent 30% of revenue in 2026, a variable cost that must be optimized as volume increases to maintain margin	$0	$3,600,000
6	R&D Licenses	Fixed Overhead	Maintaining design and engineering capabilities requires $2,100 per month for R and D Software Licenses, essential for product innovation	$2,100	$2,100
7	Marketing/Shows	Fixed Overhead	A fixed marketing budget of $6,500 per month covers trade show attendance and lead generation activities necessary for growth	$6,500	$6,500
	Total	All Operating Expenses		$73,633	$9,073,633

What is the minimum cash buffer required to cover fixed operating expenses for six months?

For your Decontamination Shower Systems business, you need a minimum cash buffer of $459,600 to cover six months of fixed operating expenses, which is critical runway before you need to worry about profitability; you can explore owner earnings potential here: How Much Does An Owner Make From Decontamination Shower Systems?. This reserve buys you time to scale sales without panic, defintely.

Six-Month Cash Need

Monthly fixed costs total $76,600.
Multiply this by 6 months for the reserve.
Required working capital is $459,600.
This covers overhead, not inventory purchases.

Runway Context

This reserve is pure operating cushion.
It covers salaries, rent, and utilities.
If sales lag in Q1 2025, you're covered.
Focus sales efforts on high-margin refinery contracts.

Which single recurring cost category represents the largest percentage of total monthly SG&A?

For your Decontamination Shower Systems business, payroll costs at $423k per month represent the single largest component of your Selling, General, and Administrative (SG&A) expenses, dwarfing the $185k facility lease. Understanding this cost structure is crucial for scaling profitably, which is why many founders look closely at the initial steps, like reviewing How Do I Launch Decontamination Shower Systems Business? to ensure operational efficiency from day one. Honestly, if you don't control headcount costs, the other levers won't matter defintely.

Payroll's Weight in SG&A

Payroll stands at $423,000 monthly, making it the dominant fixed cost.
The facility lease is $185,000, which is 43.7% of the payroll expense.
This high fixed labor cost demands high utilization rates across the team.
Variable costs, like sales commissions, need careful modeling against this base.

Controlling the Largest Driver

Tie any new hiring directly to confirmed sales pipeline value.
Analyze if sales roles can be structured to be commission-heavy.
If onboarding new hires takes 14+ days, productivity lags hurt cash flow.
Focus on increasing output per employee before approving new headcount.

How will we cover fixed costs if sales volume for high-margin units (like Modular Decon Booths) drops by 25%?

Covering the $76,600 monthly fixed overhead is the immediate concern when high-margin Modular Decon Booth sales drop by 25%, meaning you must quickly assess if the remaining contribution margin still exceeds that fixed base; for context on overall owner earnings in this space, look at How Much Does An Owner Make From Decontamination Shower Systems?. If the contribution rate on those specific booths was, say, 60%, that 25% volume reduction immediately chops 15% off your total expected contribution margin, so you're defintely facing a shortfall risk.

Margin Erosion Impact

Volume loss of 25% hits gross margin hard.
You need the original contribution rate for booths.
Calculate the new required sales volume needed.
This drop directly reduces cash flow supporting overhead.

Covering the $76,600 Hurdle

$76,600 is the minimum monthly coverage.
If the remaining contribution is below this, you lose money.
Find out how many lower-margin units compensate.
Focus on operational efficiency to lower fixed costs.

What is the total annual capital expenditure budget needed to maintain compliance and production capacity?

You need a firm view of your recurring capital needs to keep producing and staying compliant; for Decontamination Shower Systems, the 2026 schedule points to a baseline annual maintenance CAPEX of about $330,000. If you're mapping out your initial launch strategy, you should review resources like How Do I Launch Decontamination Shower Systems Business? to ensure these maintenance costs are factored into your long-term operating plan.

Fabrication Asset Replacement

The 2026 schedule pegs $220,000 for fabrication equipment replacement.
This spend maintains your ability to manufacture units at target capacity.
Failure to budget means production bottlenecks down the road.
This is defintely non-negotiable for throughput.

Certification Lab Maintenance

$110,000 is budgeted for the certification lab in 2026.
This covers calibration and replacement of testing gear.
It directly supports exceeding OSHA and ANSI Z358.1 standards.
If this lab fails, you can't sell new units legally.

Key Takeaways

The Decontamination Shower Systems business projects achieving $1.442 billion in revenue and an $886.8 million EBITDA in its first year of operation in 2026.
Maintaining operational readiness requires strictly managing the $76,600 in total monthly fixed overhead, necessitating a minimum six-month cash buffer for risk mitigation.
Variable expenses, particularly the 45% sales commissions and 30% shipping costs, represent the primary targets for immediate cash flow optimization to protect margins.
Within Selling, General, and Administrative (SG&A) expenses, the core management payroll, totaling approximately $42,333 monthly, stands out as the largest fixed cost category requiring oversight.

Running Cost 1 : Manufacturing Facility Lease

Fixed Lease Burden

Your manufacturing facility lease is a fixed overhead of $18,500 monthly. This cost hits regardless of how many decontamination showers you sell. You must track revenue per square foot closely to ensure this footprint is generating enough value to cover its fixed burden.

Facility Cost Inputs

This $18,500 covers the physical space needed to assemble and test your decontamination shower units. To budget correctly, you need the final lease agreement terms and the total square footage. Compare this fixed cost against projected revenue density, especially since other costs like sales commissions are variable.

Confirm total square footage used.
Factor in utility estimates separately.
Lock in lease term length now.

Driving Utilization

You can't easily cut this $18.5k once signed, so focus on maximizing output per square foot. This fixed cost must be covered by high-margin production runs of your decontamination units. Avoid underutilization, which kills margins defintely fast.

Track revenue density monthly.
Ensure efficient floorplan layout.
Review lease renewal options early.

Breakeven Threshold

Fixed facility costs demand high utilization thresholds. If production volume is low, this $18,500 fixed cost will eat a huge chunk of your contribution margin before core management payroll even starts. You need sales volume that justifies the physical footprint.

Running Cost 2 : Core Management Payroll

Headcount Burn Rate

Your first five essential hires cost $42,333 monthly to keep running right now. This covers the leadership needed to design and sell your decontamination shower systems, including the General Manager earning $145,000 yearly. That fixed burn rate hits before your first unit sale, so plan runway accordingly.

Payroll Calculation

This $42,333 estimate covers 5 FTE salaries plus associated employer burdens like taxes and benefits, which aren't detailed here. You need the specific annual salary for the Lead Design Engineer and the other three roles to verify this total cost. This is a core fixed operating expense you must fund monthly.

5 FTEs total headcount.
GM salary: $145,000 annually.
Need exact salary quotes now.

Managing Fixed Staff Cost

Since this is fixed, you can't cut it easily once hired. Avoid over-hiring early; make sure that Lead Design Engineer is truly necessary before Month 1. Consider using fractional executives or high-end consultants instead of full-time hires initially to defer long-term commitments and save cash.

Hire only mission-critical roles first.
Use contractors for non-core needs.
Defer hiring until revenue traction is proven.

Fixed Cost Stacking

With $42,333 in payroll, you must sell enough decontamination shower units quickly to cover this before other fixed costs like the $18,500 facility lease stack up. If the GM's $145,000 salary is based on a high-end market rate, look for competitive benchmarks defintely.

Running Cost 3 : Sales Commissions

Commissions Scale Fast

Sales commissions are your biggest lever for cost control because they hit 45% of revenue starting in 2026. If average monthly revenue hits $12 million, commissions alone cost $5.4 million monthly. You must structure sales incentives carefully to avoid margin collapse.

Calculating Commission Impact

This cost covers the direct payout to the sales team closing deals for the decontamination shower systems. Estimate this cost by multiplying projected revenue by the 45% rate. It scales instantly with every unit sold, unlike fixed payroll costs. What this estimate hides is the timing; this 45% kicks in during 2026.

Inputs: Revenue Projection × 45% Rate
Cost scales directly with sales volume
Major drag on gross margin

Controlling Sales Payouts

Managing this 45% rate means tying commissions to gross profit, not just top-line revenue. Avoid paying full commission on low-margin deals or services that require heavy post-sale support. A common mistake is rewarding volume over profitable customer acquisition; you defintely need tiered structures.

Tie payout to net profit, not gross sales
Cap commissions on specific high-cost deals
Review compensation plan annually

Margin Pressure Point

If sales commissions are 45% and shipping/logistics is 30%, your total variable cost hits 75% before accounting for manufacturing COGS. This leaves very little room for fixed overhead like the $18,500 facility lease and $42,333 core payroll.

Running Cost 4 : Product Liability Insurance

Insurance Reality Check

Because you sell safety gear for chemical exposure, product liability insurance isn't optional; it's a necessary fixed overhead. Budget for $4,200 monthly just to cover potential claims from system failure in high-risk settings. This cost protects the entire operation.

Fixed Safety Cost

This $4,200 premium covers claims if your shower fails to remove a contaminant, leading to injury. Since you deal with OSHA-regulated environments, this is a non-negotiable fixed cost, similar to the $18,500 facility lease. You need quotes based on projected sales volume and hazard classification.

Fixed monthly expense.
Covers failure in hazardous use.
Crucial for compliance.

Managing Liability Spend

You can't easily cut this premium without raising your risk profile defintely. Focus instead on locking in multi-year rates or increasing deductibles if cash flow is tight. Avoid common mistakes like understating the severity of chemicals your clients use.

Lock in multi-year pricing.
Review deductibles carefully.
Ensure accurate risk disclosure.

Overhead Impact

At $4,200 fixed, this insurance adds to your essential monthly overhead before sales commissions hit. Keep this cost stable while driving revenue through your direct sales model to improve operating leverage quickly.

Running Cost 5 : Shipping and Logistics

Logistics Cost Threat

Shipping and logistics are set to consume 30% of revenue in 2026, making it your second largest cost after sales commissions. As you scale volume for these decontamination shower systems, this variable expense will squeeze margins hard if you don't lock in favorable carrier rates now. You must manage this cost aggressively.

Logistics Cost Inputs

This 30% covers freight, insurance, and handling for shipping heavy industrial safety equipment. To model this accurately, you need quotes based on the average unit weight, destination zones (like refinery zip codes), and the required delivery speed. It's a major cost tied directly to your sales volume, not fixed overhead.

Unit weight and fragility.
Negotiated LTL carrier rates.
Target delivery window compliance.

Optimizing Freight Spend

When revenue hits $12 million monthly, small inefficiencies become huge dollar leaks. Focus on consolidating orders heading to the same industrial region or state. Avoid paying for premium service unless an OSHA deadline demands it; standard freight timelines are usually sufficient for non-emergency equipment delivery. You need to be defintely tough on carriers.

Audit all carrier invoices for accessorial fees.
Seek volume tier discounts early.
Evaluate third-party logistics providers.

Variable Cost Watch

Your largest variable cost is sales commissions at 45%, followed by shipping at 30%. If logistics creeps up to 35% due to poor volume management, your combined direct costs approach 80% of revenue. That leaves almost nothing to cover your $64,133 in core fixed operating costs like rent and payroll.

Running Cost 6 : R&D Software Licenses

License Necessity

Product innovation hinges on current design tools. For these decontamination systems, you need specialized R&D Software Licenses costing exactly $2,100 monthly. This spend keeps your engineering team current on compliance modeling and design iteration. Don't skimp here; it directly impacts your ability to meet evolving OSHA standards.

Cost Breakdown

This $2,100 covers essential CAD (Computer-Aided Design) subscriptions and simulation software required by your Lead Design Engineer. These tools enable precise fluid dynamics modeling for the shower spray patterns. It's a non-negotiable fixed cost, sitting below high-ticket items like the $42,333 core management payroll.

Covers CAD and simulation subscriptions.
Fixed cost, not tied to sales volume.
Essential for Z358.1 compliance checks.

Optimization Tactics

Reducing this spend means risking design lag or non-compliance, which is dangerous for safety equipment. Instead of cutting licenses, look at seat optimization. Ensure only active users pay annually, not monthly. If you have 5 engineers, but only 3 use high-tier packages, adjust the tier mix defintely.

Audit active user seats quarterly.
Negotiate volume discounts for annual prepay.
Avoid unused 'shelfware' licenses.

Scaling Reality

Software costs are sticky, but critical. If you plan to scale manufacturing significantly past the initial $12 million target revenue, budget for a 10% annual increase in these license fees due to required feature upgrades. That's about $252 extra per year to stay ahead.

Running Cost 7 : Marketing and Trade Shows

Fixed Marketing Budget

Your fixed marketing budget is precisely $6,500 per month, covering essential trade show attendance and lead generation activities. This spend is non-negotiable for getting your specialized decontamination showers in front of chemical manufacturers and labs who need them right now.

Marketing Allocation

This $6,500 is a fixed operating cost, separate from variable sales commissions or shipping fees. It must cover booth rentals, travel, and materials needed to capture leads from target customers like biotech facilities. You're defintely paying for access to high-value decision-makers here.

Covers trade show fees.
Funds lead capture tech.
Essential for initial growth.

Spend Efficiency

Since this cost is fixed, you can't save money by selling less; you save by selling smarter. Focus this budget only on events where your specific buyers-those handling corrosive substances-are present. Don't pay for general safety expos if your ROI isn't clear.

Target niche safety expos.
Measure leads per event.
Avoid general industry fairs.

Budget Context

At $6,500, marketing is small compared to your $42,333 core payroll or the $18,500 facility lease. Still, if trade shows don't generate enough qualified opportunities to overcome those larger fixed costs, you should pivot this budget toward digital outreach or inside sales support quickly.