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

Industrial Assessment Centers

Assessment #CO0588


Assessment Year 2006
SIC 3085
SIC Description Plastics Bottles
NAICS 326160
NAICS Description Plastics Bottle Manufacturing
Principal Product Plastic bottles
Sales $ 22,500,000
# of Employees 54
Plant Area (Sq.Ft.) 145,000
Annual Production 400,000,000 Pieces
Production Hrs. Annual 8,760
Location (State) CO
Yearly Energy Cost $ 1,545,144

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 25,560,122 kWh $ 960,261 $ 0.038 /kWh

- Demand Charge

 42,293 kW $ 583,212 $ 13.79 /kW

- Electricity Fees

 - $ 1,671 -

TOTAL ENERGY

 261,991 MMBtu $ 1,545,144 $ 5.90 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,418,959 kWh
1,401,259 kWh		 $ 53,705
$ 53,125		 5.59 %
5.53 %		 $ 0.038 /kWh

- Demand Charge

 1,416 kW
1,353 kW		 $ 19,169
$ 18,319		 3.29 %
3.14 %		 $ 13.79 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

TOTAL ENERGY

 14,546 MMBtu
14,364 MMBtu		 $ 72,874
$ 71,444		 4.72 %
4.62 %		 $ 5.90 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 9,470 $ 17,610 0.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 306,866 kWh $ 17,610 $ 0.038 /kWh

TOTAL ENERGY

 3,146 MMBtu $ 17,610 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 50 $ 9,500 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 186,200 kWh $ 6,040 $ 0.038 /kWh

- Demand Charge

 255 kW $ 3,460 $ 13.79 /kW

TOTAL ENERGY

 1,909 MMBtu $ 9,500 -
03 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 493 $ 1,244 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,193 kWh $ 785 $ 0.038 /kWh

- Demand Charge

 34 kW $ 459 $ 13.79 /kW

TOTAL ENERGY

 248 MMBtu $ 1,244 -
04 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 510 $ 200 2.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,900 kWh $ 130 $ 0.038 /kWh

- Demand Charge

 5 kW $ 70 $ 13.79 /kW

TOTAL ENERGY

 40 MMBtu $ 200 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 57,670 $ 42,290 1.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 831,100 kWh $ 26,970 $ 0.038 /kWh

- Demand Charge

 985 kW $ 13,330 $ 13.79 /kW

TOTAL ENERGY

 8,519 MMBtu $ 40,300 -

Personnel Changes

 - $ 620 -

Ancillary Material Cost

 - $ 1,370 -

TOTAL PRODUCTON

 - $ 1,990 -
06 view
details		 UTILIZE OUTSIDE AIR INSTEAD OF CONDITIONED AIR FOR DRYING 2.2711 I $ 1,310 $ 1,680 0.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,000 kWh $ 1,070 $ 0.038 /kWh

- Demand Charge

 45 kW $ 610 $ 13.79 /kW

TOTAL ENERGY

 338 MMBtu $ 1,680 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 2,970 $ 1,600 1.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,000 kWh $ 520 $ 0.038 /kWh

- Demand Charge

 29 kW $ 390 $ 13.79 /kW

TOTAL ENERGY

 164 MMBtu $ 910 -

Ancillary Material Cost

 - $ 690 -

TOTAL PRODUCTON

 - $ 690 -
08 view
details		 USE SOLAR HEAT TO MAKE ELECTRICTY 2.9114 N $ 2,950 $ 1,300 2.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,100 kWh $ 460 $ 0.038 /kWh

- Demand Charge

 62 kW $ 840 $ 13.79 /kW

TOTAL ENERGY

 145 MMBtu $ 1,300 -
09 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 390 $ 130 3.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,600 kWh $ 120 $ 0.038 /kWh

- Demand Charge

 1 kW $ 10 $ 13.79 /kW

TOTAL ENERGY

 37 MMBtu $ 130 -