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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #BD0376


Assessment Year 2010
SIC 2672
SIC Description Paper Coated And Laminated, Nec
NAICS 322222
NAICS Description Coated and Laminated Paper Manufacturing
Principal Product Pressure Sensitive Tapes
Sales $ 17,000,000
# of Employees 60
Plant Area (Sq.Ft.) 185,000
Annual Production 185 Pieces
Production Hrs. Annual 7,488
Location (State) IL
Yearly Energy Cost $ 1,023,089

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,325,200 kWh $ 255,344 $ 0.040 /kWh

- Demand Charge

 13,897 kW $ 194,569 $ 14.00 /kW

- Electricity Fees

 - $ 40,137 -

Natural Gas

 73,887 MMBtu $ 533,039 $ 7.21 /MMBtu

TOTAL ENERGY

 138,721 MMBtu $ 1,023,089 $ 7.38 /MMBtu

Water Disposal

 4,863,000 Gal $ 16,486 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 7,562 kWh
7,562 kWh		 $ 305
$ 305		 0.12 %
0.12 %		 $ 0.040 /kWh

- Demand Charge

 4,810 kW
10 kW		 $ 67,345
$ 145		 34.61 %
0.07 %		 $ 14.00 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 35,465 MMBtu
31,187 MMBtu		 $ 246,340
$ 218,752		 46.21 %
41.04 %		 $ 7.21 /MMBtu

TOTAL ENERGY

 35,543 MMBtu
31,265 MMBtu		 $ 313,990
$ 219,202		 30.69 %
21.43 %		 $ 7.38 /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)
01 view
details		 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES 2.1221 I $ 51,500 $ 105,011 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 14,585 MMBtu $ 105,011 $ 7.21 /MMBtu

TOTAL ENERGY

 14,585 MMBtu $ 105,011 -
02 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 125 $ 67,200 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 4,800 kW $ 67,200 $ 14.00 /kW

TOTAL ENERGY

 0 MMBtu $ 67,200 -
03 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 I $ 70,000 $ 62,913 1.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 8,721 MMBtu $ 62,913 $ 7.21 /MMBtu

TOTAL ENERGY

 8,721 MMBtu $ 62,913 -
04 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 I $ 34,000 $ 39,238 0.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,084 MMBtu $ 39,238 $ 7.21 /MMBtu

TOTAL ENERGY

 6,084 MMBtu $ 39,238 -
05 view
details		 INSTALL TURBULATORS 2.1222 N $ 4,350 $ 20,378 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,160 MMBtu $ 20,378 $ 7.21 /MMBtu

TOTAL ENERGY

 3,160 MMBtu $ 20,378 -
06 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 5,500 $ 11,590 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,797 MMBtu $ 11,590 $ 7.21 /MMBtu

TOTAL ENERGY

 1,797 MMBtu $ 11,590 -
07 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 9,000 $ 7,210 1.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,118 MMBtu $ 7,210 $ 7.21 /MMBtu

TOTAL ENERGY

 1,118 MMBtu $ 7,210 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 1,727 $ 989 1.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,562 kWh $ 305 $ 0.040 /kWh

- Demand Charge

 10 kW $ 145 $ 14.00 /kW

TOTAL ENERGY

 78 MMBtu $ 450 -

Personnel Changes

 - $ 380 -

Ancillary Material Cost

 - $ 159 -

TOTAL PRODUCTON

 - $ 539 -