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

Industrial Assessment Centers

Assessment #IA0446


Assessment Year 2009
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Composite pressure vessels
Sales $ 1
# of Employees 135
Plant Area (Sq.Ft.) 201,000
Annual Production 13,000 Not Available
Production Hrs. Annual 6,000
Location (State) NE
Yearly Energy Cost $ 912,176

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,629,500 kWh $ 171,045 $ 0.022 /kWh

- Demand Charge

 16,392 kW $ 262,756 $ 16.03 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 43,621 MMBtu $ 478,375 $ 10.97 /MMBtu

TOTAL ENERGY

 121,823 MMBtu $ 912,176 $ 7.49 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,235,511 kWh
1,767,009 kWh		 $ 48,730
$ 38,517		 28.49 %
22.52 %		 $ 0.022 /kWh

- Demand Charge

 3,623 kW
3,120 kW		 $ 64,549
$ 56,400		 24.57 %
21.46 %		 $ 16.03 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 10,225 MMBtu
3,072 MMBtu		 $ 117,164
$ 39,011		 24.49 %
8.15 %		 $ 10.97 /MMBtu

TOTAL ENERGY

 33,141 MMBtu
21,185 MMBtu		 $ 230,443
$ 133,928		 25.26 %
14.68 %		 $ 7.49 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 5,819 $ 6,768 0.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 124,080 kWh $ 2,705 $ 0.022 /kWh

- Demand Charge

 251 kW $ 4,063 $ 16.03 /kW

TOTAL ENERGY

 1,272 MMBtu $ 6,768 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 29,591 $ 36,189 0.82
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 667,800 kWh $ 14,555 $ 0.022 /kWh

- Demand Charge

 1,336 kW $ 21,634 $ 16.03 /kW

TOTAL ENERGY

 6,845 MMBtu $ 36,189 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 12,486 $ 17,951 0.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 331,200 kWh $ 7,221 $ 0.022 /kWh

- Demand Charge

 662 kW $ 10,730 $ 16.03 /kW

TOTAL ENERGY

 3,395 MMBtu $ 17,951 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 32,570 $ 24,368 1.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 313,628 kWh $ 6,833 $ 0.022 /kWh

- Demand Charge

 721 kW $ 17,535 $ 16.03 /kW

TOTAL ENERGY

 3,215 MMBtu $ 24,368 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 876 $ 374 2.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,140 kWh $ 374 $ 0.022 /kWh

TOTAL ENERGY

 176 MMBtu $ 374 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 268 $ 4,146 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 78,246 kWh $ 1,708 $ 0.022 /kWh

- Demand Charge

 150 kW $ 2,438 $ 16.03 /kW

TOTAL ENERGY

 802 MMBtu $ 4,146 -
07 view
details		 COVER OPEN TANKS 2.2514 N $ 20,000 $ 26,317 0.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,399 MMBtu $ 26,317 $ 10.97 /MMBtu

TOTAL ENERGY

 2,399 MMBtu $ 26,317 -
08 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 N $ 15,000 $ 23,136 0.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,110 MMBtu $ 23,136 $ 10.97 /MMBtu

TOTAL ENERGY

 2,110 MMBtu $ 23,136 -
09 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 3,180 $ 4,474 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 436 MMBtu $ 4,474 $ 10.97 /MMBtu

TOTAL ENERGY

 436 MMBtu $ 4,474 -
10 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 740 $ 4,136 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 189,742 kWh $ 4,136 $ 0.022 /kWh

TOTAL ENERGY

 1,945 MMBtu $ 4,136 -
11 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 1,860 $ 10,917 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 248,258 kWh $ 5,412 $ 0.022 /kWh

- Demand Charge

 340 kW $ 5,505 $ 16.03 /kW

TOTAL ENERGY

 2,545 MMBtu $ 10,917 -
12 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 15 $ 5,241 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 119,136 kWh $ 2,597 $ 0.022 /kWh

- Demand Charge

 163 kW $ 2,644 $ 16.03 /kW

TOTAL ENERGY

 1,221 MMBtu $ 5,241 -
13 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 N $ 1,860 $ 21,403 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,951 MMBtu $ 21,403 $ 10.97 /MMBtu

TOTAL ENERGY

 1,951 MMBtu $ 21,403 -
14 view
details		 USE HEAT FROM BOILER BLOWDOWN TO PREHEAT BOILER FEED WATER 2.1243 N $ 1,000 $ 505 1.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 46 MMBtu $ 505 $ 10.97 /MMBtu

TOTAL ENERGY

 46 MMBtu $ 505 -
15 view
details		 DIRECT WARMEST AIR TO COMBUSTION INTAKE 2.1213 N $ 213 $ 333 0.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 30 MMBtu $ 333 $ 10.97 /MMBtu

TOTAL ENERGY

 30 MMBtu $ 333 -
16 view
details		 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 2.6221 I $ 40,000 $ 16,258 2.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,614 MMBtu $ 16,258 $ 10.97 /MMBtu

TOTAL ENERGY

 1,614 MMBtu $ 16,258 -
17 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 1,461 $ 1,399 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,364 kWh $ 357 $ 0.022 /kWh

Natural Gas

 95 MMBtu $ 1,042 $ 10.97 /MMBtu

TOTAL ENERGY

 263 MMBtu $ 1,399 -
18 view
details		 TURN OFF STEAM TRACING DURING MILD WEATHER 2.2164 I $ 260 $ 957 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,193 kWh $ 244 $ 0.022 /kWh

Natural Gas

 24 MMBtu $ 713 $ 10.97 /MMBtu

TOTAL ENERGY

 139 MMBtu $ 957 -
19 view
details		 AIR CONDITION ONLY SPACE IN USE 2.7222 N $ 3,725 $ 1,847 2.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 84,744 kWh $ 1,847 $ 0.022 /kWh

TOTAL ENERGY

 869 MMBtu $ 1,847 -
20 view
details		 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 2.7243 N $ 2,600 $ 943 2.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 86 MMBtu $ 943 $ 10.97 /MMBtu

TOTAL ENERGY

 86 MMBtu $ 943 -
21 view
details		 ELIMINATE LEAKS IN WATER LINES AND VALVES 3.4154 I $ 115 $ 2,298 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Consumption

 - $ 2,298 -

TOTAL PRODUCTON

 - $ 2,298 -
22 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 I $ 15,000 $ 19,469 0.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,200 MMBtu $ 19,469 $ 10.97 /MMBtu

TOTAL ENERGY

 1,200 MMBtu $ 19,469 -
23 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 2,060 $ 3,312 0.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,980 kWh $ 741 $ 0.022 /kWh

Natural Gas

 234 MMBtu $ 2,571 $ 10.97 /MMBtu

TOTAL ENERGY

 582 MMBtu $ 3,312 -