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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #DS0132


Assessment Year 1999
SIC 2653
SIC Description Corrugated And Solid Fiber Boxes
NAICS
NAICS Description
Principal Product Corrugated Boxes
Sales $ 17,000,000
# of Employees 85
Plant Area (Sq.Ft.) 175,000
Annual Production 162,000 Thousand Feet
Production Hrs. Annual 4,290
Location (State) MN
Yearly Energy Cost $ 142,469

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,027,843 kWh $ 62,844 $ 0.031 /kWh

- Demand Charge

 6,720 kW $ 49,027 $ 7.30 /kW

- Electricity Fees

 - $ 9,843 -

Natural Gas

 1,853 MMBtu $ 9,755 $ 5.26 /MMBtu

LPG

 1,035 MMBtu $ 11,000 $ 10.63 /MMBtu

TOTAL ENERGY

 23,673 MMBtu $ 142,469 $ 6.02 /MMBtu

Water Disposal

 900,000 Gal $ 1,931 $ 0 /Gal

Other Liquid (haz)

 60 Gal $ 300 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 102,872 kWh
0 kWh		 $ 2,062
$ 0		 3.28 %
0.00 %		 $ 0.031 /kWh

- Demand Charge

 191 kW
0 kW		 $ 1,391
$ 0		 2.84 %
0.00 %		 $ 7.30 /kW

- Electricity Fees

 - $ 869
$ 0		 8.83 %
0.00 %		 -

Natural Gas

 250 MMBtu
0 MMBtu		 $ 1,316
$ 0		 13.49 %
0.00 %		 $ 5.26 /MMBtu

LPG

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 10.63 /MMBtu

TOTAL ENERGY

 1,305 MMBtu
0 MMBtu		 $ 5,638
$ 0		 3.96 %
0.00 %		 $ 6.02 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /Gal

Other Liquid (haz)

 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 TIMERS AND/OR THERMOSTATS 2.7261 N $ 1,705 $ 1,316 1.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 250 MMBtu $ 1,316 $ 5.26 /MMBtu

TOTAL ENERGY

 250 MMBtu $ 1,316 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 113 $ 947 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 40,152 kWh $ 125 $ 0.031 /kWh

- Demand Charge

 113 kW $ 822 $ 7.30 /kW

TOTAL ENERGY

 412 MMBtu $ 947 -
03 view
details		 USE POWER FACTOR CONTROLLERS 2.3211 N $ 1,750 $ 869 2.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 869 -

TOTAL ENERGY

 0 MMBtu $ 869 -
04 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 108 $ 232 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,620 kWh $ 232 $ 0.031 /kWh

TOTAL ENERGY

 78 MMBtu $ 232 -
05 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 2,274 $ 2,274 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 55,100 kWh $ 1,705 $ 0.031 /kWh

- Demand Charge

 78 kW $ 569 $ 7.30 /kW

TOTAL ENERGY

 565 MMBtu $ 2,274 -
06 view
details		 MAINTAIN MACHINES TO REDUCE LEAKS 3.7311 N $ 52 $ 2,049 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 520 lbs $ 2,049 $ 0 /lbs

TOTAL WASTE

 - $ 2,049 -
07 view
details		 CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE 4.2110 N $ 2,750 $ 5,579 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 5,579 -

TOTAL PRODUCTON

 - $ 5,579 -
08 view
details		 INSTALL SYSTEM TO COLLECT SCRAP 4.4440 N $ 6,260 $ 13,520 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 13,520 -

TOTAL PRODUCTON

 - $ 13,520 -
09 view
details		 APPLY FOR TAX-FREE STATUS FOR ENERGY PURCHASES 2.8121 N $ 90 $ 795 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 795 -

TOTAL PRODUCTON

 - $ 795 -