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

Industrial Assessment Centers

Assessment #AM0608


Assessment Year 2012
SIC 3545
SIC Description Machine Tool Accessories
NAICS 333515
NAICS Description Cutting Tool and Machine Tool Accessory Manufacturing
Principal Product Carbide drill bits
Sales $ 35,000,000
# of Employees 105
Plant Area (Sq.Ft.) 95,000
Annual Production 322,212 Pieces
Production Hrs. Annual 8,424
Location (State) TX
Yearly Energy Cost $ 763,133

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,452,982 kWh $ 593,730 $ 0.057 /kWh

- Demand Charge

 21,264 kW $ 152,481 $ 7.17 /kW

- Electricity Fees

 - $ 16,922 -

TOTAL ENERGY

 107,144 MMBtu $ 763,133 $ 7.12 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 -255,984 kWh
-1,903,951 kWh		 $ -17,475
$ -110,626		 -2.94 %
-18.63 %		 $ 0.057 /kWh

- Demand Charge

 -784 kW
-2,821 kW		 $ -5,005
$ -18,405		 -3.28 %
-12.07 %		 $ 7.17 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

TOTAL ENERGY

 -2,624 MMBtu
-19,516 MMBtu		 $ -22,480
$ -129,031		 -2.95 %
-16.91 %		 $ 7.12 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK 4.111 I $ 251,064 $ 1,383,679 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -2,670,408 kWh $ -153,281 $ 0.057 /kWh

- Demand Charge

 -3,804 kW $ -25,000 $ 7.17 /kW

TOTAL ENERGY

 -27,372 MMBtu $ -178,281 -

Personnel Changes

 - $ -38,040 -

Primary Product

 - $ 1,600,000 -

TOTAL PRODUCTON

 - $ 1,561,960 -
02 view
details		 REPLACE EXISTING HVAC UNIT WITH HIGH EFFICIENCY MODEL 2.7232 N $ 180,000 $ 90,500 1.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,345,000 kWh $ 78,000 $ 0.057 /kWh

- Demand Charge

 1,900 kW $ 12,500 $ 7.17 /kW

TOTAL ENERGY

 13,786 MMBtu $ 90,500 -
03 view
details		 RECOVER AND REUSE WASTE MATERIAL 3.5311 I $ 85,000 $ 144,150 0.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -58,815 kWh $ -4,705 $ 0.057 /kWh

- Demand Charge

 -199 kW $ -1,145 $ 7.17 /kW

TOTAL ENERGY

 -603 MMBtu $ -5,850 -

Ancillary Material Cost

 - $ 150,000 -

TOTAL PRODUCTON

 - $ 150,000 -
04 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 124,000 $ 52,200 2.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 782,472 kWh $ 44,900 $ 0.057 /kWh

- Demand Charge

 1,115 kW $ 7,300 $ 7.17 /kW

TOTAL ENERGY

 8,020 MMBtu $ 52,200 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 3,566 $ 12,691 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 221,101 kWh $ 12,691 $ 0.057 /kWh

TOTAL ENERGY

 2,266 MMBtu $ 12,691 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 65 $ 3,360 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 81,866 kWh $ 2,460 $ 0.057 /kWh

- Demand Charge

 137 kW $ 900 $ 7.17 /kW

TOTAL ENERGY

 839 MMBtu $ 3,360 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,625 $ 2,900 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,800 kWh $ 2,460 $ 0.057 /kWh

- Demand Charge

 67 kW $ 440 $ 7.17 /kW

TOTAL ENERGY

 439 MMBtu $ 2,900 -