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

Industrial Assessment Centers

Assessment #AM0614


Assessment Year 2012
SIC 3442
SIC Description Metal Doors, Sash, And Trim
NAICS 332321
NAICS Description Metal Window and Door Manufacturing
Principal Product Steel doors
Sales $ 11,200,000
# of Employees 62
Plant Area (Sq.Ft.) 60,000
Annual Production 500,000 Pieces
Production Hrs. Annual 4,000
Location (State) TX
Yearly Energy Cost $ 273,739

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,422,610 kWh $ 144,027 $ 0.059 /kWh

- Demand Charge

 10,352 kW $ 70,565 $ 6.82 /kW

- Electricity Fees

 - $ 10,975 -

Natural Gas

 9,790 MMBtu $ 48,172 $ 4.92 /MMBtu

TOTAL ENERGY

 34,622 MMBtu $ 273,739 $ 7.91 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 119,436 kWh
117,744 kWh		 $ 5,985
$ 5,900		 4.16 %
4.10 %		 $ 0.059 /kWh

- Demand Charge

 2,174 kW
2,172 kW		 $ 14,305
$ 14,290		 20.27 %
20.25 %		 $ 6.82 /kW

- Electricity Fees

 - $ 10,300
$ 10,300		 93.85 %
93.85 %		 -

Natural Gas

 8 MMBtu
0 MMBtu		 $ 30
$ 0		 0.06 %
0.00 %		 $ 4.92 /MMBtu

TOTAL ENERGY

 1,232 MMBtu
1,207 MMBtu		 $ 30,620
$ 30,490		 11.19 %
11.14 %		 $ 7.91 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 I $ 24,400 $ 12,400 1.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 1,884 kW $ 12,400 $ 6.82 /kW

TOTAL ENERGY

 0 MMBtu $ 12,400 -
02 view
details		 APPLY FOR TAX-FREE STATUS FOR ENERGY PURCHASES 2.8121 I $ 1,500 $ 51,500 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 10,300 -

TOTAL ENERGY

 0 MMBtu $ 10,300 -

One-time Revenue or Avoided Cost

 - $ 41,200 -

TOTAL PRODUCTON

 - $ 41,200 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 15 $ 3,300 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 50,000 kWh $ 2,500 $ 0.059 /kWh

- Demand Charge

 120 kW $ 800 $ 6.82 /kW

TOTAL ENERGY

 513 MMBtu $ 3,300 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 700 $ 1,800 0.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,200 kWh $ 1,300 $ 0.059 /kWh

- Demand Charge

 78 kW $ 500 $ 6.82 /kW

TOTAL ENERGY

 258 MMBtu $ 1,800 -
05 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 5,370 $ 1,500 3.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,100 kWh $ 1,010 $ 0.059 /kWh

- Demand Charge

 74 kW $ 490 $ 6.82 /kW

TOTAL ENERGY

 216 MMBtu $ 1,500 -
06 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 I $ 780 $ 700 1.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,700 kWh $ 700 $ 0.059 /kWh

TOTAL ENERGY

 140 MMBtu $ 700 -
07 view
details		 USE SYNTHETIC LUBRICANT 2.4314 I $ 0 $ 490 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,744 kWh $ 390 $ 0.059 /kWh

- Demand Charge

 16 kW $ 100 $ 6.82 /kW

TOTAL ENERGY

 79 MMBtu $ 490 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 280 $ 500 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,692 kWh $ 85 $ 0.059 /kWh

- Demand Charge

 2 kW $ 15 $ 6.82 /kW

TOTAL ENERGY

 17 MMBtu $ 100 -

Personnel Changes

 - $ 400 -

TOTAL PRODUCTON

 - $ 400 -
09 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 630 $ 30 21.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 8 MMBtu $ 30 $ 4.92 /MMBtu

TOTAL ENERGY

 8 MMBtu $ 30 -