U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #AM0537


Assessment Year 2008
SIC 2096
SIC Description Potato Chips And Similar Snacks
NAICS 311919
NAICS Description Other Snack Food Manufacturing
Principal Product Snack foods
Sales $ 337,000,000
# of Employees 500
Plant Area (Sq.Ft.) 330,000
Annual Production 108,000,000 Pounds
Production Hrs. Annual 8,740
Location (State) TX
Yearly Energy Cost $ 3,641,548

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 23,602,208 kWh $ 1,310,445 $ 0.056 /kWh

- Demand Charge

 35,733 kW $ 253,548 $ 7.10 /kW

- Electricity Fees

 - $ 34,705 -

Natural Gas

 175,851 MMBtu $ 1,728,587 $ 9.83 /MMBtu

Other Gas

 129,927 MMBtu $ 314,263 $ 2.42 /MMBtu

TOTAL ENERGY

 547,701 MMBtu $ 3,641,548 $ 6.65 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 4,335,570 kWh
3,940,070 kWh		 $ 328,340
$ 297,890		 25.06 %
22.73 %		 $ 0.056 /kWh

- Demand Charge

 6,590 kW
6,050 kW		 $ 44,855
$ 41,155		 17.69 %
16.23 %		 $ 7.10 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 69,682 MMBtu
3,222 MMBtu		 $ 375,190
$ 16,890		 21.71 %
0.98 %		 $ 9.83 /MMBtu

Other Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 2.42 /MMBtu

TOTAL ENERGY

 114,122 MMBtu
43,608 MMBtu		 $ 748,385
$ 355,935		 20.55 %
9.77 %		 $ 6.65 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE BOILER 2.1224 N $ 300,000 $ 324,000 0.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 60,100 MMBtu $ 324,000 $ 9.83 /MMBtu

TOTAL ENERGY

 60,100 MMBtu $ 324,000 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 750,000 $ 260,000 2.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,973,550 kWh $ 229,000 $ 0.056 /kWh

- Demand Charge

 4,560 kW $ 31,000 $ 7.10 /kW

TOTAL ENERGY

 30,479 MMBtu $ 260,000 -
03 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,500 $ 42,100 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 487,000 kWh $ 37,500 $ 0.056 /kWh

- Demand Charge

 676 kW $ 4,600 $ 7.10 /kW

TOTAL ENERGY

 4,992 MMBtu $ 42,100 -
04 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 25,000 $ 34,300 0.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,360 MMBtu $ 34,300 $ 9.83 /MMBtu

TOTAL ENERGY

 6,360 MMBtu $ 34,300 -
05 view
details		 UPGRADE CONVEYORS 2.4325 N $ 80,000 $ 34,150 2.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 395,500 kWh $ 30,450 $ 0.056 /kWh

- Demand Charge

 540 kW $ 3,700 $ 7.10 /kW

TOTAL ENERGY

 4,054 MMBtu $ 34,150 -
06 view
details		 USE STEAM PRESSURE REDUCTION TO GENERATE POWER 2.3321 I $ 59,850 $ 18,255 3.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 264,000 kWh $ 14,800 $ 0.056 /kWh

- Demand Charge

 507 kW $ 3,455 $ 7.10 /kW

TOTAL ENERGY

 2,706 MMBtu $ 18,255 -
07 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 12,000 $ 15,000 0.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,800 MMBtu $ 15,000 $ 9.83 /MMBtu

TOTAL ENERGY

 2,800 MMBtu $ 15,000 -
08 view
details		 USE SYNTHETIC LUBRICANT 2.4314 I $ 0 $ 9,930 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 114,800 kWh $ 8,840 $ 0.056 /kWh

- Demand Charge

 159 kW $ 1,090 $ 7.10 /kW

TOTAL ENERGY

 1,177 MMBtu $ 9,930 -
09 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 47,740 $ 7,480 6.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 86,640 kWh $ 6,670 $ 0.056 /kWh

- Demand Charge

 119 kW $ 810 $ 7.10 /kW

TOTAL ENERGY

 888 MMBtu $ 7,480 -
10 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 1,460 $ 3,150 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,130 kWh $ 470 $ 0.056 /kWh

- Demand Charge

 8 kW $ 60 $ 7.10 /kW

TOTAL ENERGY

 63 MMBtu $ 530 -

Personnel Changes

 - $ 2,620 -

TOTAL PRODUCTON

 - $ 2,620 -
11 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 I $ 500 $ 1,890 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 422 MMBtu $ 1,890 $ 9.83 /MMBtu

TOTAL ENERGY

 422 MMBtu $ 1,890 -
12 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 0 $ 750 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,950 kWh $ 610 $ 0.056 /kWh

- Demand Charge

 21 kW $ 140 $ 7.10 /kW

TOTAL ENERGY

 81 MMBtu $ 750 -