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

Industrial Assessment Centers

Assessment #BD0302


Assessment Year 2006
SIC 3842
SIC Description Surgical Appliances And Supplies
NAICS 339113
NAICS Description Surgical Appliance and Supplies Manufacturing
Principal Product Orthodics and Ankle Braces
Sales $ 8,000,000
# of Employees 90
Plant Area (Sq.Ft.) 40,000
Annual Production 122,000 Pieces
Production Hrs. Annual 2,210
Location (State) IL
Yearly Energy Cost $ 81,208

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 979,300 kWh $ 61,419 $ 0.063 /kWh

- Demand Charge

 4,179 kW $ 9,814 $ 2.35 /kW

- Electricity Fees

 - $ 3,283 -

Natural Gas

 617 MMBtu $ 6,692 $ 10.85 /MMBtu

TOTAL ENERGY

 10,655 MMBtu $ 81,208 $ 7.62 /MMBtu

Water Disposal

 9,298 Gal $ 4,797 $ 1 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 183,514 kWh
90,570 kWh		 $ 9,818
$ 4,001		 15.99 %
6.51 %		 $ 0.063 /kWh

- Demand Charge

 521 kW
46 kW		 $ 1,248
$ 108		 12.72 %
1.10 %		 $ 2.35 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 321 MMBtu
104 MMBtu		 $ 2,829
$ 1,130		 42.27 %
16.89 %		 $ 10.85 /MMBtu

TOTAL ENERGY

 2,202 MMBtu
1,032 MMBtu		 $ 13,895
$ 5,239		 17.11 %
6.45 %		 $ 7.62 /MMBtu

Water Disposal

 7,800 Gal
0 Gal		 $ 2,375
$ 0		 49.51 %
0.00 %		 $ 1 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 0 $ 3,774 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 50,016 kWh $ 3,136 $ 0.063 /kWh

- Demand Charge

 272 kW $ 638 $ 2.35 /kW

TOTAL ENERGY

 513 MMBtu $ 3,774 -
02 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 0 $ 3,381 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 80,683 kWh $ 3,381 $ 0.063 /kWh

TOTAL ENERGY

 827 MMBtu $ 3,381 -
03 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 5,000 $ 1,699 2.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 217 MMBtu $ 1,699 $ 10.85 /MMBtu

TOTAL ENERGY

 217 MMBtu $ 1,699 -
04 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 0 $ 1,130 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 104 MMBtu $ 1,130 $ 10.85 /MMBtu

TOTAL ENERGY

 104 MMBtu $ 1,130 -
05 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 N $ 260 $ 848 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,608 kWh $ 728 $ 0.063 /kWh

- Demand Charge

 51 kW $ 120 $ 2.35 /kW

TOTAL ENERGY

 119 MMBtu $ 848 -
06 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 1,050 $ 835 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,285 kWh $ 696 $ 0.063 /kWh

- Demand Charge

 49 kW $ 139 $ 2.35 /kW

TOTAL ENERGY

 116 MMBtu $ 835 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 0 $ 1 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1 kWh $ 1 $ 0.063 /kWh

TOTAL ENERGY

 0 MMBtu $ 1 -
08 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 1,550 $ 1,195 1.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,124 kWh $ 1,011 $ 0.063 /kWh

- Demand Charge

 78 kW $ 184 $ 2.35 /kW

TOTAL ENERGY

 165 MMBtu $ 1,195 -
09 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 384 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,263 kWh $ 330 $ 0.063 /kWh

- Demand Charge

 23 kW $ 54 $ 2.35 /kW

TOTAL ENERGY

 54 MMBtu $ 384 -
10 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 I $ 500 $ 344 1.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,624 kWh $ 290 $ 0.063 /kWh

- Demand Charge

 23 kW $ 54 $ 2.35 /kW

TOTAL ENERGY

 47 MMBtu $ 344 -
11 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 N $ 2,550 $ 304 8.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,910 kWh $ 245 $ 0.063 /kWh

- Demand Charge

 25 kW $ 59 $ 2.35 /kW

TOTAL ENERGY

 40 MMBtu $ 304 -
12 view
details		 MINIMIZE WATER USAGE 3.4151 N $ 1,725 $ 2,375 0.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 7,800 Gal $ 2,375 $ 1 /Gal

TOTAL WASTE

 - $ 2,375 -