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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #IA0357


Assessment Year 2004
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product window components
Sales $ 30,000,000
# of Employees 150
Plant Area (Sq.Ft.) 60,000
Annual Production 2,500,000 Pounds
Production Hrs. Annual 6,240
Location (State) SD
Yearly Energy Cost $ 220,781

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,667,040 kWh $ 89,705 $ 0.034 /kWh

- Demand Charge

 5,760 kW $ 46,320 $ 8.04 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 11,810 MMBtu $ 84,756 $ 7.18 /MMBtu

TOTAL ENERGY

 39,147 MMBtu $ 220,781 $ 5.64 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 -81,136 kWh
-104,224 kWh		 $ -2,741
$ -3,514		 -3.06 %
-3.92 %		 $ 0.034 /kWh

- Demand Charge

 1,314 kW
1,269 kW		 $ 10,896
$ 10,544		 23.52 %
22.76 %		 $ 8.04 /kW

- Electricity Fees

 - $ 1,879
$ 1,879		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 7.18 /MMBtu

TOTAL ENERGY

 -832 MMBtu
-1,068 MMBtu		 $ 10,034
$ 8,909		 4.54 %
4.04 %		 $ 5.64 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 I $ 2,445 $ 1,879 1.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 1,879 -

TOTAL ENERGY

 0 MMBtu $ 1,879 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 349 $ 1,225 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,194 kWh $ 1,115 $ 0.034 /kWh

- Demand Charge

 64 kW $ 510 $ 8.04 /kW

TOTAL ENERGY

 340 MMBtu $ 1,625 -

Personnel Changes

 - $ -400 -

TOTAL PRODUCTON

 - $ -400 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 25 $ 1,125 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,088 kWh $ 773 $ 0.034 /kWh

- Demand Charge

 44 kW $ 352 $ 8.04 /kW

TOTAL ENERGY

 237 MMBtu $ 1,125 -
04 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 262 $ 657 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,479 kWh $ 452 $ 0.034 /kWh

- Demand Charge

 26 kW $ 205 $ 8.04 /kW

TOTAL ENERGY

 138 MMBtu $ 657 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 23 $ 8,027 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 159,609 kWh $ 5,350 $ 0.034 /kWh

- Demand Charge

 337 kW $ 2,677 $ 8.04 /kW

TOTAL ENERGY

 1,636 MMBtu $ 8,027 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 654 $ 447 1.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,169 kWh $ 307 $ 0.034 /kWh

- Demand Charge

 18 kW $ 140 $ 8.04 /kW

TOTAL ENERGY

 94 MMBtu $ 447 -
07 view
details		 INSTALL REFRIGERATION SYSTEM TO COOL PRODUCT 4.1130 I $ 145,850 $ 206,874 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -319,675 kWh $ -10,738 $ 0.034 /kWh

- Demand Charge

 825 kW $ 7,012 $ 8.04 /kW

TOTAL ENERGY

 -3,277 MMBtu $ -3,726 -

Personnel Changes

 - $ 210,600 -

TOTAL PRODUCTON

 - $ 210,600 -