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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #BD0410


Assessment Year 2012
SIC 3625
SIC Description Relays And Industrial Controls
NAICS 335314
NAICS Description Relay and Industrial Control Manufacturing
Principal Product Residential electrical enclosures
Sales $ 133,667,000
# of Employees 472
Plant Area (Sq.Ft.) 386,000
Annual Production 3,296,651 Pieces
Production Hrs. Annual 5,355
Location (State) IL
Yearly Energy Cost $ 1,071,489

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,611,220 kWh $ 521,290 $ 0.049 /kWh

- Demand Charge

 23,713 kW $ 26,627 $ 1.12 /kW

- Electricity Fees

 - $ 58,780 -

Natural Gas

 98,111 MMBtu $ 464,792 $ 4.74 /MMBtu

TOTAL ENERGY

 206,877 MMBtu $ 1,071,489 $ 5.18 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 504,870 kWh
0 kWh		 $ 24,788
$ 0		 4.76 %
0.00 %		 $ 0.049 /kWh

- Demand Charge

 1,424 kW
0 kW		 $ 1,595
$ 0		 5.99 %
0.00 %		 $ 1.12 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 3,523 MMBtu
0 MMBtu		 $ 16,694
$ 0		 3.59 %
0.00 %		 $ 4.74 /MMBtu

TOTAL ENERGY

 8,698 MMBtu
0 MMBtu		 $ 43,077
$ 0		 4.02 %
0.00 %		 $ 5.18 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 5,500 $ 14,500 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,060 MMBtu $ 14,500 $ 4.74 /MMBtu

TOTAL ENERGY

 3,060 MMBtu $ 14,500 -
02 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 20 $ 11,850 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 229,703 kWh $ 11,278 $ 0.049 /kWh

- Demand Charge

 510 kW $ 572 $ 1.12 /kW

TOTAL ENERGY

 2,354 MMBtu $ 11,850 -
03 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 10,000 $ 821 12.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -2,920 kWh $ -143 $ 0.049 /kWh

- Demand Charge

 -6 kW $ -7 $ 1.12 /kW

Natural Gas

 205 MMBtu $ 971 $ 4.74 /MMBtu

TOTAL ENERGY

 175 MMBtu $ 821 -
04 view
details		 USE PHOTOCELL CONTROLS 2.7134 N $ 4,050 $ 4,755 0.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 88,641 kWh $ 4,352 $ 0.049 /kWh

- Demand Charge

 360 kW $ 403 $ 1.12 /kW

TOTAL ENERGY

 909 MMBtu $ 4,755 -
05 view
details		 USE SYNTHETIC LUBRICANT 2.4314 N $ 1,000 $ 3,095 0.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 59,922 kWh $ 2,942 $ 0.049 /kWh

- Demand Charge

 137 kW $ 153 $ 1.12 /kW

TOTAL ENERGY

 614 MMBtu $ 3,095 -
06 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 N $ 4,900 $ 2,832 1.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,868 kWh $ 2,694 $ 0.049 /kWh

- Demand Charge

 123 kW $ 138 $ 1.12 /kW

TOTAL ENERGY

 562 MMBtu $ 2,832 -
07 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 2,025 $ 2,094 0.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 37,704 kWh $ 1,851 $ 0.049 /kWh

- Demand Charge

 217 kW $ 243 $ 1.12 /kW

TOTAL ENERGY

 386 MMBtu $ 2,094 -
08 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 500 $ 1,907 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 36,952 kWh $ 1,814 $ 0.049 /kWh

- Demand Charge

 83 kW $ 93 $ 1.12 /kW

TOTAL ENERGY

 379 MMBtu $ 1,907 -
09 view
details		 INSTALL AUTOMATIC STACK DAMPER 2.1123 N $ 1,750 $ 1,223 1.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 258 MMBtu $ 1,223 $ 4.74 /MMBtu

TOTAL ENERGY

 258 MMBtu $ 1,223 -