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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #AM0618


Assessment Year 2012
SIC 3496
SIC Description Misc. Fabricated Wire Products
NAICS 332618
NAICS Description Other Fabricated Wire Product Manufacturing
Principal Product Wire products and displays
Sales $ 15,000,000
# of Employees 108
Plant Area (Sq.Ft.) 295,000
Annual Production 15,000 Pieces
Production Hrs. Annual 2,350
Location (State) TX
Yearly Energy Cost $ 592,911

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,707,192 kWh $ 242,564 $ 0.090 /kWh

- Demand Charge

 10,705 kW $ 158,306 $ 14.79 /kW

- Electricity Fees

 - $ 10,433 -

Natural Gas

 24,208 MMBtu $ 181,608 $ 7.50 /MMBtu

TOTAL ENERGY

 51,957 MMBtu $ 592,911 $ 11.41 /MMBtu

Solid Waste (non-haz)

 706,000 lbs $ 23,700 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 170,660 kWh
0 kWh		 $ 10,990
$ 0		 4.53 %
0.00 %		 $ 0.090 /kWh

- Demand Charge

 852 kW
0 kW		 $ 5,430
$ 0		 3.43 %
0.00 %		 $ 14.79 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 7.50 /MMBtu

TOTAL ENERGY

 1,749 MMBtu
0 MMBtu		 $ 16,420
$ 0		 2.77 %
0.00 %		 $ 11.41 /MMBtu

Solid Waste (non-haz)

 706,000 lbs
0 lbs		 $ 23,700
$ 0		 100.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE A LESS EXPENSIVE METHOD OF WASTE REMOVAL 3.6192 $ 0 $ 23,700 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 706,000 lbs $ 23,700 $ 0 /lbs

TOTAL WASTE

 - $ 23,700 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 $ 500 $ 8,050 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 83,800 kWh $ 5,350 $ 0.090 /kWh

- Demand Charge

 424 kW $ 2,700 $ 14.79 /kW

TOTAL ENERGY

 859 MMBtu $ 8,050 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 $ 17,720 $ 6,200 2.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 63,600 kWh $ 4,130 $ 0.090 /kWh

- Demand Charge

 325 kW $ 2,070 $ 14.79 /kW

TOTAL ENERGY

 652 MMBtu $ 6,200 -
04 view
details		 REUSE RAGS UNTIL COMPLETELY SOILED 3.7132 $ 0 $ 2,230 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 2,230 -

TOTAL PRODUCTON

 - $ 2,230 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 $ 920 $ 1,940 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,560 kWh $ 360 $ 0.090 /kWh

- Demand Charge

 8 kW $ 50 $ 14.79 /kW

TOTAL ENERGY

 57 MMBtu $ 410 -

Personnel Changes

 - $ 1,530 -

TOTAL PRODUCTON

 - $ 1,530 -
06 view
details		 CONVERT TO HIGH VOLUME LOW PRESSURE (HVLP) PAINT GUNS 3.2123 $ 190 $ 1,000 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 1,000 -

TOTAL PRODUCTON

 - $ 1,000 -
07 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 $ 0 $ 750 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,400 kWh $ 480 $ 0.090 /kWh

- Demand Charge

 42 kW $ 270 $ 14.79 /kW

TOTAL ENERGY

 76 MMBtu $ 750 -
08 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 $ 25 $ 650 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,600 kWh $ 430 $ 0.090 /kWh

- Demand Charge

 34 kW $ 220 $ 14.79 /kW

TOTAL ENERGY

 68 MMBtu $ 650 -
09 view
details		 USE SYNTHETIC LUBRICANT 2.4314 $ 0 $ 360 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,700 kWh $ 240 $ 0.090 /kWh

- Demand Charge

 19 kW $ 120 $ 14.79 /kW

TOTAL ENERGY

 38 MMBtu $ 360 -