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

Industrial Assessment Centers

Assessment #IA0436


Assessment Year 2009
SIC 3714
SIC Description Motor Vehicle Parts And Accessories
NAICS 336370
NAICS Description Motor Vehicle Metal Stamping
Principal Product metal stampings and welded assemblies
Sales $ 145,500
# of Employees 390
Plant Area (Sq.Ft.) 189,433
Annual Production 11,294,317 Pieces
Production Hrs. Annual 4,000
Location (State) IA
Yearly Energy Cost $ 1,063,220

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 17,184,510 kWh $ 777,180 $ 0.045 /kWh

- Demand Charge

 3,107 kW $ 37,046 $ 11.92 /kW

- Electricity Fees

 - $ 10,123 -

Natural Gas

 23,616 MMBtu $ 238,871 $ 10.11 /MMBtu

TOTAL ENERGY

 199,757 MMBtu $ 1,063,220 $ 5.32 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 627,208 kWh
33,840 kWh		 $ 28,168
$ 1,523		 3.62 %
0.20 %		 $ 0.045 /kWh

- Demand Charge

 1,783 kW
8 kW		 $ 22,434
$ 1,210		 60.56 %
3.27 %		 $ 11.92 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,755 MMBtu
0 MMBtu		 $ 17,998
$ 0		 7.53 %
0.00 %		 $ 10.11 /MMBtu

TOTAL ENERGY

 8,184 MMBtu
347 MMBtu		 $ 68,600
$ 2,733		 6.45 %
0.26 %		 $ 5.32 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,739 $ 2,733 1.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,840 kWh $ 1,523 $ 0.045 /kWh

- Demand Charge

 8 kW $ 1,210 $ 11.92 /kW

TOTAL ENERGY

 347 MMBtu $ 2,733 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 1,974 $ 1,163 1.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,400 kWh $ 648 $ 0.045 /kWh

- Demand Charge

 43 kW $ 515 $ 11.92 /kW

TOTAL ENERGY

 148 MMBtu $ 1,163 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 52,246 $ 21,522 2.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 266,400 kWh $ 11,988 $ 0.045 /kWh

- Demand Charge

 799 kW $ 9,534 $ 11.92 /kW

TOTAL ENERGY

 2,731 MMBtu $ 21,522 -
04 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,283 $ 8,802 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 89,500 kWh $ 4,027 $ 0.045 /kWh

- Demand Charge

 396 kW $ 4,775 $ 11.92 /kW

TOTAL ENERGY

 917 MMBtu $ 8,802 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 1,136 $ 14,400 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 179,040 kWh $ 8,000 $ 0.045 /kWh

- Demand Charge

 537 kW $ 6,400 $ 11.92 /kW

TOTAL ENERGY

 1,835 MMBtu $ 14,400 -
06 view
details		 VENTILATION SYSTEM TO SHUT OFF WHEN ROOM IS NOT IN USE 2.7311 N $ 2,400 $ 10,850 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,150 MMBtu $ 10,850 $ 10.11 /MMBtu

TOTAL ENERGY

 1,150 MMBtu $ 10,850 -
07 view
details		 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 2.7243 N $ 472 $ 2,098 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 222 MMBtu $ 2,098 $ 10.11 /MMBtu

TOTAL ENERGY

 222 MMBtu $ 2,098 -
08 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 539 $ 1,982 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 44,028 kWh $ 1,982 $ 0.045 /kWh

TOTAL ENERGY

 451 MMBtu $ 1,982 -
09 view
details		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 N $ 7,884 $ 5,050 1.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 383 MMBtu $ 5,050 $ 10.11 /MMBtu

TOTAL ENERGY

 383 MMBtu $ 5,050 -