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

Industrial Assessment Centers

Assessment #IA0484


Assessment Year 2012
SIC 3081
SIC Description Unsupported Plastics Film & Sheet
NAICS 326113
NAICS Description Unlaminated Plastics Film and Sheet (except Packaging) Manufacturing
Principal Product Expandable Foam
Sales $ 11,000,000
# of Employees 60
Plant Area (Sq.Ft.) 82,500
Annual Production 4,800,000 Pounds
Production Hrs. Annual 6,120
Location (State) IA
Yearly Energy Cost $ 509,784

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,876,000 kWh $ 101,967 $ 0.035 /kWh

- Demand Charge

 6,268 kW $ 92,576 $ 14.77 /kW

- Electricity Fees

 - $ 6,775 -

Natural Gas

 58,142 MMBtu $ 308,466 $ 5.31 /MMBtu

TOTAL ENERGY

 87,621 MMBtu $ 509,784 $ 5.82 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 345,766 kWh
0 kWh		 $ 12,206
$ 0		 11.97 %
0.00 %		 $ 0.035 /kWh

- Demand Charge

 701 kW
0 kW		 $ 10,031
$ 0		 10.84 %
0.00 %		 $ 14.77 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 610 MMBtu
0 MMBtu		 $ 3,239
$ 0		 1.05 %
0.00 %		 $ 5.31 /MMBtu

TOTAL ENERGY

 4,154 MMBtu
0 MMBtu		 $ 25,476
$ 0		 5.00 %
0.00 %		 $ 5.82 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 DIRECT WARMEST AIR TO COMBUSTION INTAKE 2.1213 $ 401 $ 2,225 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 419 MMBtu $ 2,225 $ 5.31 /MMBtu

TOTAL ENERGY

 419 MMBtu $ 2,225 -
02 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 $ 390 $ 664 0.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,365 kWh $ 225 $ 0.035 /kWh

- Demand Charge

 30 kW $ 439 $ 14.77 /kW

TOTAL ENERGY

 65 MMBtu $ 664 -
03 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 $ 1,424 $ 442 3.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,460 kWh $ 442 $ 0.035 /kWh

TOTAL ENERGY

 128 MMBtu $ 442 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 $ 799 $ 769 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,996 kWh $ 424 $ 0.035 /kWh

- Demand Charge

 24 kW $ 345 $ 14.77 /kW

TOTAL ENERGY

 123 MMBtu $ 769 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 $ 11,275 $ 10,589 1.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 181,348 kWh $ 6,401 $ 0.035 /kWh

- Demand Charge

 286 kW $ 4,188 $ 14.77 /kW

TOTAL ENERGY

 1,859 MMBtu $ 10,589 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 $ 971 $ 2,822 0.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,790 kWh $ 1,686 $ 0.035 /kWh

- Demand Charge

 95 kW $ 1,136 $ 14.77 /kW

TOTAL ENERGY

 490 MMBtu $ 2,822 -
07 view
details		 RE-SIZE CHARGING OPENINGS OR ADD MOVABLE COVER OR DOOR 2.2531 $ 1,466 $ 1,014 1.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 191 MMBtu $ 1,014 $ 5.31 /MMBtu

TOTAL ENERGY

 191 MMBtu $ 1,014 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 $ 250 $ 1,427 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,278 kWh $ 786 $ 0.035 /kWh

- Demand Charge

 43 kW $ 641 $ 14.77 /kW

TOTAL ENERGY

 228 MMBtu $ 1,427 -
09 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 $ 7,700 $ 4,537 1.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 48,882 kWh $ 1,726 $ 0.035 /kWh

- Demand Charge

 192 kW $ 2,811 $ 14.77 /kW

TOTAL ENERGY

 501 MMBtu $ 4,537 -
10 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 $ 1,009 $ 987 1.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,647 kWh $ 516 $ 0.035 /kWh

- Demand Charge

 32 kW $ 471 $ 14.77 /kW

TOTAL ENERGY

 150 MMBtu $ 987 -