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

Industrial Assessment Centers

Assessment #GT0725


Assessment Year 2002
SIC 2657
SIC Description Folding Paperboard Boxes
NAICS
NAICS Description
Principal Product Secondary Paperboard Packages
Sales $ 152,000,000
# of Employees 225
Plant Area (Sq.Ft.) 1,000,000
Annual Production 1,175,000 Pieces
Production Hrs. Annual 8,400
Location (State) GA
Yearly Energy Cost $ 1,664,850

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 18,405,154 kWh $ 908,386 $ 0.049 /kWh

- Electricity Fees

 - $ 63,587 -

Natural Gas

 107,994 MMBtu $ 692,877 $ 6.42 /MMBtu

TOTAL ENERGY

 296,647 MMBtu $ 1,664,850 $ 5.61 /MMBtu

Water Disposal

 492,000 Gal $ 20,627 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 403,385 kWh
302,123 kWh		 $ 14,075
$ 10,566		 1.55 %
1.16 %		 $ 0.049 /kWh

- Electricity Fees

 - $ 3,371
$ 3,122		 5.30 %
4.91 %		 -

Natural Gas

 -1,592 MMBtu
-345 MMBtu		 $ -7,965
$ -1,725		 -1.15 %
-0.25 %		 $ 6.42 /MMBtu

TOTAL ENERGY

 5,827 MMBtu
2,752 MMBtu		 $ 45,181
$ 11,963		 2.71 %
0.72 %		 $ 5.61 /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		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 I $ 10,500 $ 43,102 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 81,000 kWh $ 2,827 $ 0.049 /kWh

Natural Gas

 -345 MMBtu $ -1,725 $ 6.42 /MMBtu

TOTAL ENERGY

 485 MMBtu $ 1,102 -

Personnel Changes

 - $ 2,000 -

Ancillary Material Cost

 - $ 40,000 -

TOTAL PRODUCTON

 - $ 42,000 -
02 view
details		 INSTALL SYSTEM TO COLLECT SCRAP 4.4440 N $ 192,000 $ 540,000 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 540,000 -

TOTAL PRODUCTON

 - $ 540,000 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 3,758 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 101,262 kWh $ 3,509 $ 0.049 /kWh

- Electricity Fees

 - $ 249 -

TOTAL ENERGY

 1,038 MMBtu $ 3,758 -
04 view
details		 INSTALL SPECTRAL REFLECTORS / DELAMP 2.7144 I $ 2,550 $ 2,446 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 65,324 kWh $ 2,286 $ 0.049 /kWh

- Electricity Fees

 - $ 160 -

TOTAL ENERGY

 670 MMBtu $ 2,446 -
05 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 N $ 35,000 $ 10,185 3.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,037 MMBtu $ 10,185 $ 6.42 /MMBtu

TOTAL ENERGY

 2,037 MMBtu $ 10,185 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 10,007 $ 4,301 2.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 114,839 kWh $ 4,019 $ 0.049 /kWh

- Electricity Fees

 - $ 282 -

TOTAL ENERGY

 1,177 MMBtu $ 4,301 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 400 $ 4,114 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 40,960 kWh $ 1,434 $ 0.049 /kWh

- Electricity Fees

 - $ 2,680 -

TOTAL ENERGY

 420 MMBtu $ 4,114 -
08 view
details		 FILTER AND REUSE HYDRAULIC OIL 3.5111 I $ 0 $ 1,900 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ -600 -

Ancillary Material Cost

 - $ 2,500 -

TOTAL PRODUCTON

 - $ 1,900 -
09 view
details		 CONVERT COMBUSTION EQUIPMENT TO BURN NATURAL GAS 2.1332 N $ 45,000 $ 19,275 2.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 -3,284 MMBtu $ -16,425 $ 6.42 /MMBtu

LPG

 3,284 MMBtu $ 35,700 $ 0.00 /MMBtu

TOTAL ENERGY

 0 MMBtu $ 19,275 -