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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #GT0630


Assessment Year 1997
SIC 3149
SIC Description Footwear, Except Rubber, Nec
NAICS
NAICS Description
Principal Product Footwear
Sales $ 30,000,000
# of Employees 185
Plant Area (Sq.Ft.) 64,225
Annual Production 612,000 Pieces
Production Hrs. Annual 3,920
Location (State) GA
Yearly Energy Cost $ 244,466

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,696,366 kWh $ 80,887 $ 0.030 /kWh

- Demand Charge

 11,309 kW $ 126,208 $ 11.16 /kW

- Electricity Fees

 - $ 14,357 -

LPG

 2,821 MMBtu $ 23,014 $ 8.16 /MMBtu

TOTAL ENERGY

 30,459 MMBtu $ 244,466 $ 8.03 /MMBtu

Solid Waste (non-haz)

 122,500 lbs $ 1,633 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 217,761 kWh
217,761 kWh		 $ 6,620
$ 6,620		 8.18 %
8.18 %		 $ 0.030 /kWh

- Demand Charge

 1,116 kW
592 kW		 $ 12,464
$ 6,616		 9.88 %
5.24 %		 $ 11.16 /kW

- Electricity Fees

 - $ 1,119
$ 767		 7.79 %
5.34 %		 -

LPG

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 8.16 /MMBtu

TOTAL ENERGY

 2,232 MMBtu
2,232 MMBtu		 $ 20,203
$ 14,003		 8.26 %
5.73 %		 $ 8.03 /MMBtu

Solid Waste (non-haz)

 326,000 lbs
264,000 lbs		 $ 8,340
$ 7,540		 510.72 %
461.73 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 20,800 $ 6,900 3.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 94,959 kWh $ 2,847 $ 0.030 /kWh

- Demand Charge

 328 kW $ 3,669 $ 11.16 /kW

- Electricity Fees

 - $ 384 -

TOTAL ENERGY

 973 MMBtu $ 6,900 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 4,370 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 66,237 kWh $ 1,989 $ 0.030 /kWh

- Demand Charge

 192 kW $ 2,143 $ 11.16 /kW

- Electricity Fees

 - $ 238 -

TOTAL ENERGY

 679 MMBtu $ 4,370 -
03 view
details		 DISCONNECT BALLASTS 2.7122 I $ 280 $ 153 1.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,758 kWh $ 50 $ 0.030 /kWh

- Demand Charge

 8 kW $ 94 $ 11.16 /kW

- Electricity Fees

 - $ 9 -

TOTAL ENERGY

 18 MMBtu $ 153 -
04 view
details		 COMBINE UTILITY METERS 2.8112 N $ 0 $ 2,920 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 2,920 -

TOTAL PRODUCTON

 - $ 2,920 -
05 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 3,900 $ 6,200 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 524 kW $ 5,848 $ 11.16 /kW

- Electricity Fees

 - $ 352 -

TOTAL ENERGY

 0 MMBtu $ 6,200 -
06 view
details		 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER 3.5315 I $ 6,700 $ 7,540 0.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 264,000 lbs $ 7,540 $ 0 /lbs

TOTAL WASTE

 - $ 7,540 -
07 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 2,580 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,807 kWh $ 1,734 $ 0.030 /kWh

- Demand Charge

 64 kW $ 710 $ 11.16 /kW

- Electricity Fees

 - $ 136 -

TOTAL ENERGY

 562 MMBtu $ 2,580 -
08 view
details		 RECOVER AND REUSE WASTE MATERIAL 3.5311 N $ 0 $ 800 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 62,000 lbs $ 800 $ 0 /lbs

TOTAL WASTE

 - $ 800 -
09 view
details		 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE LABOR COSTS 4.5130 N $ 26,600 $ 17,600 1.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 17,600 -

TOTAL PRODUCTON

 - $ 17,600 -