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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #BD0285

Assessment Year	2005
SIC	2514
SIC Description	Metal Household Furniture
NAICS	337124
NAICS Description	Metal Household Furniture Manufacturing
Principal Product	Bed Frames
Sales	$ 40,000,000
# of Employees	200
Plant Area (Sq.Ft.)	125,000
Annual Production	225,000 Pieces
Production Hrs. Annual	3,770
Location (State)	MO
Yearly Energy Cost	$ 176,983

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	1,855,425 kWh	$ 89,439	$ 0.048 /kWh
- Demand Charge	5,321 kW	$ 11,049	$ 2.08 /kW
- Electricity Fees	-	$ 6,368	-
Natural Gas	7,571 MMBtu	$ 70,127	$ 9.26 /MMBtu
TOTAL ENERGY	26,589 MMBtu	$ 176,983	$ 6.66 /MMBtu
Water Disposal	1,749,000 Gal	$ 3,713	$ 0 /Gal

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	155,684 kWh 140,770 kWh	$ 7,505 $ 6,786	8.39 % 7.59 %	$ 0.048 /kWh
- Demand Charge	3,682 kW 926 kW	$ 5,097 $ 1,923	46.13 % 17.40 %	$ 2.08 /kW
- Electricity Fees	-	$ 0 $ 0	0.00 % 0.00 %	-
Natural Gas	0 MMBtu 0 MMBtu	$ 0 $ 0	0.00 % 0.00 %	$ 9.26 /MMBtu
TOTAL ENERGY	1,596 MMBtu 1,443 MMBtu	$ 12,602 $ 8,709	7.12 % 4.92 %	$ 6.66 /MMBtu
Water Disposal	0 Gal 0 Gal	$ 0 $ 0	0.00 % 0.00 %	$ 0 /Gal

Recommendations

AR #

Description

ARC Code

Status

Cost

Savings

Payback
(Years)

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details

USE MORE EFFICIENT LIGHT SOURCE

2.7143

$ 2,695

$ 3,090

0.87

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	47,486 kWh	$ 2,289	$ 0.048 /kWh
- Demand Charge	274 kW	$ 570	$ 2.08 /kW
TOTAL ENERGY	487 MMBtu	$ 2,859	-
Personnel Changes	-	$ 79	-
Ancillary Material Cost	-	$ 152	-
TOTAL PRODUCTON	-	$ 231	-

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details

USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS

2.4133

$ 4,080

$ 2,976

1.37

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	54,299 kWh	$ 2,617	$ 0.048 /kWh
- Demand Charge	173 kW	$ 359	$ 2.08 /kW
TOTAL ENERGY	557 MMBtu	$ 2,976	-

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details

REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED

2.4231

$ 0

$ 1,695

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	28,163 kWh	$ 1,357	$ 0.048 /kWh
- Demand Charge	163 kW	$ 338	$ 2.08 /kW
TOTAL ENERGY	289 MMBtu	$ 1,695	-

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details

INSTALL OCCUPANCY SENSORS

2.7135

$ 675

$ 995

0.68

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	14,914 kWh	$ 719	$ 0.048 /kWh
- Demand Charge	1,363 kW	$ 276	$ 2.08 /kW
TOTAL ENERGY	153 MMBtu	$ 995	-

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details

INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS

2.4221

$ 900

$ 487

1.85

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	6,827 kWh	$ 330	$ 0.048 /kWh
- Demand Charge	75 kW	$ 157	$ 2.08 /kW
TOTAL ENERGY	70 MMBtu	$ 487	-

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details

RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS

2.3131

$ 0

$ 488

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
- Demand Charge	235 kW	$ 488	$ 2.08 /kW
TOTAL ENERGY	0 MMBtu	$ 488	-

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details

USE MORE EFFICIENT LIGHT SOURCE

2.7143

$ 360

$ 370

0.97

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	3,995 kWh	$ 193	$ 0.048 /kWh
- Demand Charge	6 kW	$ 11	$ 2.08 /kW
TOTAL ENERGY	41 MMBtu	$ 204	-
Personnel Changes	-	$ 69	-
Ancillary Material Cost	-	$ 97	-
TOTAL PRODUCTON	-	$ 166	-

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details

CONTRACT A WOOD PALLET RECYCLING COMPANY

3.5316

$ 480

$ 11,600

0.04

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Solid Waste (non-haz)	78,000 lbs	$ 11,600	$ 0 /lbs
TOTAL WASTE	-	$ 11,600	-

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details

MINIMIZE WATER USAGE

3.4151

$ 1,320

$ 3,135

0.42

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Consumption	-	$ 3,135	-
TOTAL PRODUCTON	-	$ 3,135	-

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details

CHANGE OPERATING CONDITIONS

4.6320

$ 2,500

$ 2,898

0.86

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
- Demand Charge	1,393 kW	$ 2,898	$ 2.08 /kW
TOTAL ENERGY	0 MMBtu	$ 2,898	-