Unplanned production cost

Hi friends,
We have an issue related to implementation in textile industry. 
There is a type of cost which is 'drawing / knoting' ...it is actually a preprocessing exp....but for a particular type of textile.....there can be multiple production orders using this preparatory process..  This cost is for a specific number of looms.......
In actual practice if in case of urgency they may use more looms and 'drawing' cost will be more...
So the problem is we cannot plan it correctly ...and also it is a one time initial cost of production...
Clint wants to charge this cost to the production orders on a later stage.....based on the actual scenario...
How can we do this??? 
Even if we charge tis to production orders by some method.....it will end up in production variance...which is not correct??!!!...
Can we keep it seperately and charge to COPA against the gross margin????/  but in that case it will not reflect in actual cost!!!
Please suggest a good solution for this issue...
thanks in advance...
Ramesan

Hi Ajay, Thanks for your reply
Let me elabourate it more....
Industry- Textile:-
There are some pre production activities which cant be added in routing. Such as Drawing, Knoting,
which is not specific to a production order. It is for a serios of Production Orders.
Let say Drawing happened for a particular material x. the same will be used for different production orders until unless the material change. The same is true for Knoting also. These expenses cant be included in routing because this operation is not required for  every production order.it is a onetime expenses and must for a series of production orders of same type of material.
How to bring this into both standard and actual expenses avoiding variance.
Alternative-1
collecting these costs to a cost center and bring to copa through assessment.
Advantage- The cost is distributed over the gross profit of the material
Disadvantage- It is not considered as production cost and not included in stock.
Alternative-2
Include in Activity
Advantage- included in production and stock and no variance.
Disadvantage- This expenses booked in one production order where as othere production orders with out this cost. I.e 1st PO overloaded and other PO are not charged. 
Please, suggest if any better way is there.

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