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U.S. Department of Energy Energy Efficiency and Renewable Energy
IAC Field Managers

Industrial Assessment Centers

Assessment #AM0499


Assessment Year 2005
SIC 3411
SIC Description Metal Cans
NAICS 332431
NAICS Description Metal Can Manufacturing
Principal Product Aluminum beverage cans
Sales $ 82,000,000
# of Employees 130
Plant Area (Sq.Ft.) 241,200
Annual Production 2,000,000,000 Pieces
Production Hrs. Annual 8,688
Location (State) TX
Yearly Energy Cost $ 2,793,431

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 33,350,000 kWh $ 1,682,447 $ 0.050 /kWh

- Demand Charge

 51,986 kW $ 403,384 $ 7.76 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 113,920 MMBtu $ 707,600 $ 6.21 /MMBtu

TOTAL ENERGY

 455,758 MMBtu $ 2,793,431 $ 6.13 /MMBtu

Recommended Reduction in Usage & Costs

Recommended
Implemented
Energy Sources Yearly Savings Yearly Cost % Saved Unit Price

Electricity

 678,125 kWh
671,225 kWh		 $ 37,295
$ 36,915		 2.22 %
2.19 %		 $ 0.050 /kWh

- Demand Charge

 1,203 kW
931 kW		 $ 10,390
$ 8,040		 2.58 %
1.99 %		 $ 7.76 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 120 MMBtu
0 MMBtu		 $ 775
$ 0		 0.11 %
0.00 %		 $ 6.21 /MMBtu

TOTAL ENERGY

 7,072 MMBtu
6,881 MMBtu		 $ 48,460
$ 44,955		 1.73 %
1.61 %		 $ 6.13 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 27,700 $ 12,800 2.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 191,200 kWh $ 10,520 $ 0.050 /kWh

- Demand Charge

 264 kW $ 2,280 $ 7.76 /kW

TOTAL ENERGY

 1,960 MMBtu $ 12,800 -
02 view
details		 REUSE RAGS UNTIL COMPLETELY SOILED 3.7132 I $ 0 $ 12,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 12,000 -

TOTAL PRODUCTON

 - $ 12,000 -
03 view
details		 USE SYNTHETIC LUBRICANT 2.4314 I $ 0 $ 11,335 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 169,375 kWh $ 9,315 $ 0.050 /kWh

- Demand Charge

 234 kW $ 2,020 $ 7.76 /kW

TOTAL ENERGY

 1,736 MMBtu $ 11,335 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 2,800 $ 11,110 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 166,100 kWh $ 9,130 $ 0.050 /kWh

- Demand Charge

 229 kW $ 1,980 $ 7.76 /kW

TOTAL ENERGY

 1,703 MMBtu $ 11,110 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 0 $ 8,975 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 134,100 kWh $ 7,375 $ 0.050 /kWh

- Demand Charge

 185 kW $ 1,600 $ 7.76 /kW

TOTAL ENERGY

 1,375 MMBtu $ 8,975 -
06 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 5,600 $ 2,270 2.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 263 kW $ 2,270 $ 7.76 /kW

TOTAL ENERGY

 0 MMBtu $ 2,270 -
07 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 1,080 $ 2,380 0.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,900 kWh $ 380 $ 0.050 /kWh

- Demand Charge

 9 kW $ 80 $ 7.76 /kW

TOTAL ENERGY

 71 MMBtu $ 460 -

Ancillary Material Cost

 - $ 1,920 -

TOTAL PRODUCTON

 - $ 1,920 -
08 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 0 $ 735 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,450 kWh $ 575 $ 0.050 /kWh

- Demand Charge

 19 kW $ 160 $ 7.76 /kW

TOTAL ENERGY

 107 MMBtu $ 735 -
09 view
details		 INCREASE INSULATION THICKNESS 2.2512 N $ 35 $ 505 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 80 MMBtu $ 505 $ 6.21 /MMBtu

TOTAL ENERGY

 80 MMBtu $ 505 -
10 view
details		 INCREASE INSULATION THICKNESS 2.2512 N $ 40 $ 270 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 40 MMBtu $ 270 $ 6.21 /MMBtu

TOTAL ENERGY

 40 MMBtu $ 270 -