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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #HO0154


Assessment Year 1997
SIC 3931
SIC Description Musical Instruments
NAICS
NAICS Description
Principal Product Guitars
Sales $ 45,000,000
# of Employees 400
Plant Area (Sq.Ft.) 18,000
Annual Production 24,000 Pieces
Production Hrs. Annual 5,200
Location (State) PA
Yearly Energy Cost $ 364,926

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,076,788 kWh $ 127,481 $ 0.041 /kWh

- Demand Charge

 9,581 kW $ 91,499 $ 9.55 /kW

- Electricity Fees

 - $ 3,755 -

Natural Gas

 20,868 MMBtu $ 142,191 $ 6.81 /MMBtu

TOTAL ENERGY

 52,405 MMBtu $ 364,926 $ 6.96 /MMBtu

Other Liquid (haz)

 10,600 Gal $ 6,900 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 98,183 kWh
93,787 kWh		 $ 4,059
$ 3,881		 3.18 %
3.04 %		 $ 0.041 /kWh

- Demand Charge

 216 kW
216 kW		 $ 2,063
$ 2,063		 2.25 %
2.25 %		 $ 9.55 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 891 MMBtu
-53 MMBtu		 $ 6,062
$ -363		 4.26 %
-0.26 %		 $ 6.81 /MMBtu

TOTAL ENERGY

 1,897 MMBtu
908 MMBtu		 $ 12,184
$ 5,581		 3.34 %
1.53 %		 $ 6.96 /MMBtu

Other Liquid (haz)

 4,240 Gal
4,240 Gal		 $ 2,926
$ 2,926		 42.41 %
42.41 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 21,668 $ 5,944 3.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 93,787 kWh $ 3,881 $ 0.041 /kWh

- Demand Charge

 216 kW $ 2,063 $ 9.55 /kW

TOTAL ENERGY

 961 MMBtu $ 5,944 -
02 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 N $ 575 $ 178 3.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,396 kWh $ 178 $ 0.041 /kWh

TOTAL ENERGY

 45 MMBtu $ 178 -
03 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 3,182 $ 6,425 0.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 944 MMBtu $ 6,425 $ 6.81 /MMBtu

TOTAL ENERGY

 944 MMBtu $ 6,425 -
04 view
details		 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE LABOR COSTS 4.5130 N $ 10,800 $ 15,600 0.69
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 15,600 -

TOTAL PRODUCTON

 - $ 15,600 -
05 view
details		 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK 4.1110 N $ 525,000 $ 117,000 4.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 117,000 -

TOTAL PRODUCTON

 - $ 117,000 -
06 view
details		 USE EVAPORATION TO CONCENTRATE MATERIAL 3.3131 I $ 10,000 $ 2,563 3.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 -53 MMBtu $ -363 $ 6.81 /MMBtu

TOTAL ENERGY

 -53 MMBtu $ -363 -

Other Liquid (haz)

 4,240 Gal $ 2,926 $ 0 /Gal

TOTAL WASTE

 - $ 2,926 -