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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #GT0873


Assessment Year 2010
SIC 3085
SIC Description Plastics Bottles
NAICS 326160
NAICS Description Plastics Bottle Manufacturing
Principal Product Plastic Containers
Sales $ 20,000,000
# of Employees 53
Plant Area (Sq.Ft.) 200,000
Annual Production 32,000,000 Pieces
Production Hrs. Annual 8,760
Location (State) GA
Yearly Energy Cost $ 495,467

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,799,280 kWh $ 449,782 $ 0.058 /kWh

- Demand Charge

 16,591 kW $ 0 $ 0.00 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 4,154 MMBtu $ 45,685 $ 11.00 /MMBtu

TOTAL ENERGY

 84,097 MMBtu $ 495,467 $ 5.89 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 705,896 kWh
197,255 kWh		 $ 42,488
$ 11,919		 9.45 %
2.65 %		 $ 0.058 /kWh

- Demand Charge

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

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 972 MMBtu
972 MMBtu		 $ 10,688
$ 10,688		 23.39 %
23.39 %		 $ 11.00 /MMBtu

TOTAL ENERGY

 8,206 MMBtu
2,993 MMBtu		 $ 53,176
$ 22,607		 10.73 %
4.56 %		 $ 5.89 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 6,353 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 105,706 kWh $ 6,353 $ 0.058 /kWh

TOTAL ENERGY

 1,083 MMBtu $ 6,353 -
02 view
details		 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 2.2614 N $ 4,600 $ 10,144 0.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 178,767 kWh $ 10,744 $ 0.058 /kWh

TOTAL ENERGY

 1,832 MMBtu $ 10,744 -

Ancillary Material Cost

 - $ -600 -

TOTAL PRODUCTON

 - $ -600 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 19,768 $ 19,825 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 329,874 kWh $ 19,825 $ 0.058 /kWh

TOTAL ENERGY

 3,381 MMBtu $ 19,825 -
04 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 10,640 $ 3,777 2.82
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 62,842 kWh $ 3,777 $ 0.058 /kWh

TOTAL ENERGY

 644 MMBtu $ 3,777 -
05 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 4,400 $ 816 5.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,574 kWh $ 816 $ 0.058 /kWh

TOTAL ENERGY

 139 MMBtu $ 816 -
06 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 I $ 775 $ 11,661 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 15,133 kWh $ 973 $ 0.058 /kWh

Natural Gas

 972 MMBtu $ 10,688 $ 11.00 /MMBtu

TOTAL ENERGY

 1,127 MMBtu $ 11,661 -