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

Industrial Assessment Centers

Assessment #BD0406


Assessment Year 2012
SIC 2099
SIC Description Food Preparations, Nec
NAICS 311991
NAICS Description Perishable Prepared Food Manufacturing
Principal Product Heat and serve entrees
Sales $ 30,000,000
# of Employees 85
Plant Area (Sq.Ft.) 30,578
Annual Production 85,000,000 Pounds
Production Hrs. Annual 3,756
Location (State) IL
Yearly Energy Cost $ 231,316

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,361,263 kWh $ 107,931 $ 0.046 /kWh

- Demand Charge

 5,913 kW $ 26,623 $ 4.50 /kW

- Electricity Fees

 - $ 23,944 -

Natural Gas

 9,970 MMBtu $ 72,818 $ 7.30 /MMBtu

TOTAL ENERGY

 34,173 MMBtu $ 231,316 $ 6.77 /MMBtu

Water Disposal

 5,249,464 Gal $ 26,781 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 903,867 kWh
96,693 kWh		 $ 42,005
$ 4,419		 38.92 %
4.09 %		 $ 0.046 /kWh

- Demand Charge

 747 kW
233 kW		 $ 3,359
$ 1,047		 12.62 %
3.93 %		 $ 4.50 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 5,106 MMBtu
1,255 MMBtu		 $ 37,293
$ 9,166		 51.21 %
12.59 %		 $ 7.30 /MMBtu

TOTAL ENERGY

 14,371 MMBtu
2,246 MMBtu		 $ 82,657
$ 14,632		 35.73 %
6.33 %		 $ 6.77 /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		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 N $ 4,573 $ 31,639 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 630,868 kWh $ 28,831 $ 0.046 /kWh

TOTAL ENERGY

 6,466 MMBtu $ 28,831 -

Personnel Changes

 - $ 2,808 -

TOTAL PRODUCTON

 - $ 2,808 -
02 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 800 $ 15,397 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,108 MMBtu $ 15,397 $ 7.30 /MMBtu

TOTAL ENERGY

 2,108 MMBtu $ 15,397 -
03 view
details		 DIRECT WARMEST AIR TO COMBUSTION INTAKE 2.1213 N $ 10,000 $ 12,730 0.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,743 MMBtu $ 12,730 $ 7.30 /MMBtu

TOTAL ENERGY

 1,743 MMBtu $ 12,730 -
04 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 I $ 3,000 $ 8,394 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,149 MMBtu $ 8,394 $ 7.30 /MMBtu

TOTAL ENERGY

 1,149 MMBtu $ 8,394 -
05 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 7,591 $ 4,151 1.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,083 kWh $ 3,156 $ 0.046 /kWh

- Demand Charge

 221 kW $ 995 $ 4.50 /kW

TOTAL ENERGY

 708 MMBtu $ 4,151 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 3,404 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 65,611 kWh $ 2,999 $ 0.046 /kWh

- Demand Charge

 90 kW $ 405 $ 4.50 /kW

TOTAL ENERGY

 673 MMBtu $ 3,404 -
07 view
details		 COOL COMPRESSOR AIR INTAKE WITH HEAT EXCHANGER 2.4234 N $ 9,400 $ 2,394 3.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 32,675 kWh $ 2,192 $ 0.046 /kWh

- Demand Charge

 45 kW $ 202 $ 4.50 /kW

TOTAL ENERGY

 335 MMBtu $ 2,394 -
08 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 N $ 3,350 $ 2,126 1.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,354 kWh $ 1,616 $ 0.046 /kWh

- Demand Charge

 113 kW $ 510 $ 4.50 /kW

TOTAL ENERGY

 362 MMBtu $ 2,126 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 2,736 $ 1,962 1.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,938 kWh $ 1,460 $ 0.046 /kWh

- Demand Charge

 112 kW $ 502 $ 4.50 /kW

TOTAL ENERGY

 327 MMBtu $ 1,962 -
10 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 1,350 $ 1,808 0.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,859 kWh $ 1,227 $ 0.046 /kWh

- Demand Charge

 129 kW $ 581 $ 4.50 /kW

TOTAL ENERGY

 275 MMBtu $ 1,808 -
11 view
details		 INSTALL TURBULATORS 2.1222 I $ 1,500 $ 772 1.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 106 MMBtu $ 772 $ 7.30 /MMBtu

TOTAL ENERGY

 106 MMBtu $ 772 -
12 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 150 $ 434 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,256 kWh $ 332 $ 0.046 /kWh

- Demand Charge

 23 kW $ 103 $ 4.50 /kW

TOTAL ENERGY

 74 MMBtu $ 434 -
13 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 10 $ 254 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,223 kWh $ 193 $ 0.046 /kWh

- Demand Charge

 14 kW $ 61 $ 4.50 /kW

TOTAL ENERGY

 43 MMBtu $ 254 -
14 view
details		 RECOVER AND REUSE COOLING WATER 3.4115 N $ 2,200 $ 15,696 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Consumption

 - $ 15,696 -

TOTAL PRODUCTON

 - $ 15,696 -