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

Industrial Assessment Centers

Assessment #GT0882


Assessment Year 2011
SIC 3429
SIC Description Hardware, Nec
NAICS 336399
NAICS Description All Other Motor Vehicle Parts Manufacturing
Principal Product Automotive Locking Mechanism
Sales $ 62,900,000
# of Employees 440
Plant Area (Sq.Ft.) 325,000
Annual Production 11,900,000 Pieces
Production Hrs. Annual 5,880
Location (State) GA
Yearly Energy Cost $ 1,435,537

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 13,514,048 kWh $ 447,590 $ 0.033 /kWh

- Demand Charge

 46,402 kW $ 627,820 $ 13.53 /kW

- Electricity Fees

 - $ 36,140 -

Natural Gas

 40,816 MMBtu $ 323,987 $ 7.94 /MMBtu

TOTAL ENERGY

 179,336 MMBtu $ 1,435,537 $ 8.00 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,838,629 kWh
3,401,353 kWh		 $ 127,058
$ 112,585		 28.39 %
25.15 %		 $ 0.033 /kWh

- Demand Charge

 3,132 kW
1,392 kW		 $ 42,376
$ 18,834		 6.75 %
3.00 %		 $ 13.53 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 10,414 MMBtu
0 MMBtu		 $ 82,687
$ 0		 25.52 %
0.00 %		 $ 7.94 /MMBtu

TOTAL ENERGY

 49,760 MMBtu
34,864 MMBtu		 $ 252,121
$ 131,419		 17.56 %
9.15 %		 $ 8.00 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 0 $ 13,634 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 562,970 kWh $ 18,634 $ 0.033 /kWh

TOTAL ENERGY

 5,771 MMBtu $ 18,634 -

Ancillary Material Cost

 - $ -5,000 -

TOTAL PRODUCTON

 - $ -5,000 -
02 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 0 $ 7,201 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 217,560 kWh $ 7,201 $ 0.033 /kWh

TOTAL ENERGY

 2,230 MMBtu $ 7,201 -
03 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 70,000 $ 28,143 2.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 139,010 kWh $ 4,601 $ 0.033 /kWh

- Demand Charge

 1,740 kW $ 23,542 $ 13.53 /kW

TOTAL ENERGY

 1,425 MMBtu $ 28,143 -
04 view
details		 METER WASTE WATER 3.4155 N $ 6,000 $ 3,614 1.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 790,000 Gal $ 3,614 $ 0 /Gal

TOTAL WASTE

 - $ 3,614 -
05 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 55,000 $ 16,076 3.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 485,673 kWh $ 16,076 $ 0.033 /kWh

TOTAL ENERGY

 4,978 MMBtu $ 16,076 -
06 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 136,000 $ 31,792 4.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 960,476 kWh $ 31,792 $ 0.033 /kWh

TOTAL ENERGY

 9,845 MMBtu $ 31,792 -
07 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 I $ 38,640 $ 17,800 2.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 537,772 kWh $ 17,800 $ 0.033 /kWh

TOTAL ENERGY

 5,512 MMBtu $ 17,800 -
08 view
details		 USE "HEAT WHEEL" OR OTHER HEAT EXCHANGER TO CROSS-EXCHANGE BUILDING EXHAUST AIR WITH MAKE-UP AIR 2.2492 N $ 222,000 $ 85,358 2.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 80,706 kWh $ 2,671 $ 0.033 /kWh

Natural Gas

 10,414 MMBtu $ 82,687 $ 7.94 /MMBtu

TOTAL ENERGY

 11,241 MMBtu $ 85,358 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 155,150 $ 47,117 3.29
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 854,462 kWh $ 28,283 $ 0.033 /kWh

- Demand Charge

 1,392 kW $ 18,834 $ 13.53 /kW

TOTAL ENERGY

 8,758 MMBtu $ 47,117 -