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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #GT0785


Assessment Year 2004
SIC 2052
SIC Description Cookies And Crackers
NAICS 311821
NAICS Description Cookie and Cracker Manufacturing
Principal Product PACKAGING FOOD
Sales $ 178,000,000
# of Employees 230
Plant Area (Sq.Ft.) 225,000
Annual Production 14,000,000 Pieces
Production Hrs. Annual 6,240
Location (State) AL
Yearly Energy Cost $ 255,699

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,737,355 kWh $ 91,292 $ 0.024 /kWh

- Demand Charge

 8,283 kW $ 119,377 $ 14.41 /kW

- Electricity Fees

 - $ 20,283 -

Natural Gas

 2,043 MMBtu $ 24,747 $ 12.11 /MMBtu

TOTAL ENERGY

 40,351 MMBtu $ 255,699 $ 6.34 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 591,544 kWh
285,100 kWh		 $ 17,744
$ 8,549		 19.44 %
9.36 %		 $ 0.024 /kWh

- Demand Charge

 607 kW
243 kW		 $ 9,336
$ 3,738		 7.82 %
3.13 %		 $ 14.41 /kW

- Electricity Fees

 - $ 12,100
$ 0		 59.66 %
0.00 %		 -

Natural Gas

 515 MMBtu
0 MMBtu		 $ 4,247
$ 0		 17.16 %
0.00 %		 $ 12.11 /MMBtu

TOTAL ENERGY

 6,578 MMBtu
2,922 MMBtu		 $ 43,427
$ 12,287		 16.98 %
4.81 %		 $ 6.34 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 2.8114 N $ 0 $ 12,100 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 12,100 -

TOTAL ENERGY

 0 MMBtu $ 12,100 -
02 view
details		 SHIFT FROM DAYTIME TO NIGHTTIME OPERATION 2.3134 N $ 0 $ 4,460 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 290 kW $ 4,460 $ 14.41 /kW

TOTAL ENERGY

 0 MMBtu $ 4,460 -
03 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 1,870 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 62,400 kWh $ 1,870 $ 0.024 /kWh

TOTAL ENERGY

 640 MMBtu $ 1,870 -
04 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 1,200 $ 2,757 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,000 kWh $ 1,619 $ 0.024 /kWh

- Demand Charge

 74 kW $ 1,138 $ 14.41 /kW

TOTAL ENERGY

 554 MMBtu $ 2,757 -
05 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 2,240 $ 4,570 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,634 kWh $ 323 $ 0.024 /kWh

Natural Gas

 515 MMBtu $ 4,247 $ 12.11 /MMBtu

TOTAL ENERGY

 624 MMBtu $ 4,570 -
06 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 150 $ 223 0.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,410 kWh $ 223 $ 0.024 /kWh

TOTAL ENERGY

 76 MMBtu $ 223 -
07 view
details		 METER WASTE WATER 3.4155 N $ 2,500 $ 1,900 1.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 0 Gal $ 1,900 $ 0 /Gal

TOTAL WASTE

 - $ 1,900 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 2,500 $ 1,360 1.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,400 kWh $ 1,360 $ 0.024 /kWh

TOTAL ENERGY

 465 MMBtu $ 1,360 -
09 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 3,030 $ 1,630 1.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,500 kWh $ 1,630 $ 0.024 /kWh

TOTAL ENERGY

 559 MMBtu $ 1,630 -
10 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 N $ 8,400 $ 5,400 1.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 179,900 kWh $ 5,400 $ 0.024 /kWh

TOTAL ENERGY

 1,844 MMBtu $ 5,400 -
11 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,250 $ 9,057 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 177,300 kWh $ 5,319 $ 0.024 /kWh

- Demand Charge

 243 kW $ 3,738 $ 14.41 /kW

TOTAL ENERGY

 1,817 MMBtu $ 9,057 -