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

Industrial Assessment Centers

Assessment #DL0053


Assessment Year 2010
SIC 2834
SIC Description Pharmaceutical Preparations
NAICS 325412
NAICS Description Pharmaceutical Preparation Manufacturing
Principal Product Pharmaceuticals
Sales $ 56,000,000
# of Employees 400
Plant Area (Sq.Ft.) 612,277
Annual Production 1 Not Available
Production Hrs. Annual 4,210
Location (State) DE
Yearly Energy Cost $ 5,506,609

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 35,762,484 kWh $ 3,618,409 $ 0.101 /kWh

- Demand Charge

 5,341 kW $ 16,235 $ 3.04 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 187,861 MMBtu $ 1,871,965 $ 9.96 /MMBtu

TOTAL ENERGY

 554,426 MMBtu $ 5,506,609 $ 9.93 /MMBtu

Water Disposal

 21,093,000 Gal $ 93,052 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 4,722,522 kWh
4,586,522 kWh		 $ 497,000
$ 482,900		 13.74 %
13.35 %		 $ 0.101 /kWh

- Demand Charge

 0 kW
0 kW		 $ 0
$ 0		 0.00 %
0.00 %		 $ 3.04 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 56,206 MMBtu
36,386 MMBtu		 $ 541,600
$ 344,600		 28.93 %
18.41 %		 $ 9.96 /MMBtu

TOTAL ENERGY

 104,613 MMBtu
83,399 MMBtu		 $ 1,038,600
$ 827,500		 18.86 %
15.03 %		 $ 9.93 /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		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 4,000 $ 358,000 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,920,000 kWh $ 202,000 $ 0.101 /kWh

Natural Gas

 17,100 MMBtu $ 156,000 $ 9.96 /MMBtu

TOTAL ENERGY

 36,780 MMBtu $ 358,000 -
02 view
details		 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 2.6221 N $ 760 $ 142,000 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 14,300 MMBtu $ 142,000 $ 9.96 /MMBtu

TOTAL ENERGY

 14,300 MMBtu $ 142,000 -
03 view
details		 ADD AREA LIGHTING SWITCHES 2.7131 I $ 29,200 $ 123,000 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,167,000 kWh $ 123,000 $ 0.101 /kWh

TOTAL ENERGY

 11,962 MMBtu $ 123,000 -
04 view
details		 INCREASE AMOUNT OF CONDENSATE RETURNED 2.2121 I $ 60,000 $ 58,000 1.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,240 MMBtu $ 39,000 $ 9.96 /MMBtu

TOTAL ENERGY

 4,240 MMBtu $ 39,000 -

Water Consumption

 - $ 19,000 -

TOTAL PRODUCTON

 - $ 19,000 -
05 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 30,000 $ 80,000 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 8,036 MMBtu $ 80,000 $ 9.96 /MMBtu

TOTAL ENERGY

 8,036 MMBtu $ 80,000 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 700 $ 74,000 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 702,000 kWh $ 74,000 $ 0.101 /kWh

TOTAL ENERGY

 7,196 MMBtu $ 74,000 -
07 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 10,000 $ 55,000 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 5,520 MMBtu $ 55,000 $ 9.96 /MMBtu

TOTAL ENERGY

 5,520 MMBtu $ 55,000 -
08 view
details		 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 2.6221 I $ 20 $ 61,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,136 MMBtu $ 61,000 $ 9.96 /MMBtu

TOTAL ENERGY

 6,136 MMBtu $ 61,000 -
09 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 10,240 $ 40,900 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 389,522 kWh $ 40,900 $ 0.101 /kWh

TOTAL ENERGY

 3,993 MMBtu $ 40,900 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,920 $ 10,000 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 97,000 kWh $ 10,000 $ 0.101 /kWh

TOTAL ENERGY

 994 MMBtu $ 10,000 -
11 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 I $ 10 $ 6,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 614 MMBtu $ 6,000 $ 9.96 /MMBtu

TOTAL ENERGY

 614 MMBtu $ 6,000 -
12 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 500 $ 4,100 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,000 kWh $ 4,100 $ 0.101 /kWh

TOTAL ENERGY

 400 MMBtu $ 4,100 -
13 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 100 $ 2,600 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 260 MMBtu $ 2,600 $ 9.96 /MMBtu

TOTAL ENERGY

 260 MMBtu $ 2,600 -
14 view
details		 ESTABLISH EQUIPMENT MAINTENANCE SCHEDULE 2.6124 I $ 8,600 $ 18,000 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 172,000 kWh $ 18,000 $ 0.101 /kWh

TOTAL ENERGY

 1,763 MMBtu $ 18,000 -
15 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 31,440 $ 25,000 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 236,000 kWh $ 25,000 $ 0.101 /kWh

TOTAL ENERGY

 2,419 MMBtu $ 25,000 -