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

Industrial Assessment Centers

Assessment #IC0131


Assessment Year 2007
SIC 3714
SIC Description Motor Vehicle Parts And Accessories
NAICS 423120
NAICS Description Motor Vehicle Supplies and New Parts Merchant Wholesalers
Principal Product automotive part and supplies
Sales $ 120,000,000
# of Employees 215
Plant Area (Sq.Ft.) 155,000
Annual Production 6,652,000 Pieces
Production Hrs. Annual 7,176
Location (State) IL
Yearly Energy Cost $ 392,486

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,602,386 kWh $ 235,880 $ 0.051 /kWh

- Demand Charge

 11,482 kW $ 128,745 $ 11.21 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 3,496 MMBtu $ 27,861 $ 7.97 /MMBtu

TOTAL ENERGY

 50,670 MMBtu $ 392,486 $ 7.75 /MMBtu

Other Liquid (non-haz)

 1,226,720 Gal $ 6,223 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 859,645 kWh
805,004 kWh		 $ 40,355
$ 37,733		 17.11 %
16.00 %		 $ 0.051 /kWh

- Demand Charge

 1,606 kW
1,539 kW		 $ 17,622
$ 16,872		 13.69 %
13.10 %		 $ 11.21 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 299 MMBtu
179 MMBtu		 $ 2,383
$ 1,427		 8.55 %
5.12 %		 $ 7.97 /MMBtu

TOTAL ENERGY

 9,110 MMBtu
8,430 MMBtu		 $ 60,360
$ 56,032		 15.38 %
14.28 %		 $ 7.75 /MMBtu

Other Liquid (non-haz)

 505,936 Gal
505,936 Gal		 $ 2,578
$ 2,578		 41.43 %
41.43 %		 $ 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 $ 65,800 $ 16,220 4.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 272,975 kWh $ 13,103 $ 0.051 /kWh

- Demand Charge

 456 kW $ 5,112 $ 11.21 /kW

TOTAL ENERGY

 2,798 MMBtu $ 18,215 -

Ancillary Material Cost

 - $ -1,995 -

TOTAL PRODUCTON

 - $ -1,995 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 105,762 $ 14,150 7.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 216,256 kWh $ 10,380 $ 0.051 /kWh

- Demand Charge

 362 kW $ 4,058 $ 11.21 /kW

TOTAL ENERGY

 2,217 MMBtu $ 14,438 -

Personnel Changes

 - $ 1,071 -

Ancillary Material Cost

 - $ -1,359 -

TOTAL PRODUCTON

 - $ -288 -
03 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 3,681 $ 1,159 3.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,700 kWh $ 1,042 $ 0.051 /kWh

- Demand Charge

 36 kW $ 404 $ 11.21 /kW

TOTAL ENERGY

 222 MMBtu $ 1,446 -

Personnel Changes

 - $ 134 -

Ancillary Material Cost

 - $ -421 -

TOTAL PRODUCTON

 - $ -287 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 6,442 $ 1,771 3.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,600 kWh $ 1,660 $ 0.051 /kWh

- Demand Charge

 10 kW $ 111 $ 11.21 /kW

TOTAL ENERGY

 355 MMBtu $ 1,771 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 677 $ 516 1.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,005 kWh $ 145 $ 0.051 /kWh

- Demand Charge

 14 kW $ 157 $ 11.21 /kW

TOTAL ENERGY

 31 MMBtu $ 302 -

Personnel Changes

 - $ 219 -

Ancillary Material Cost

 - $ -5 -

TOTAL PRODUCTON

 - $ 214 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 930 $ 149 6.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 876 kWh $ 42 $ 0.051 /kWh

- Demand Charge

 1 kW $ 11 $ 11.21 /kW

TOTAL ENERGY

 9 MMBtu $ 53 -

Personnel Changes

 - $ 46 -

Ancillary Material Cost

 - $ 50 -

TOTAL PRODUCTON

 - $ 96 -
07 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 N $ 0 $ 87 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,095 kWh $ 53 $ 0.051 /kWh

- Demand Charge

 3 kW $ 34 $ 11.21 /kW

TOTAL ENERGY

 11 MMBtu $ 87 -
08 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 8,430 $ 1,867 4.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,437 kWh $ 981 $ 0.051 /kWh

- Demand Charge

 79 kW $ 886 $ 11.21 /kW

TOTAL ENERGY

 209 MMBtu $ 1,867 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 3,192 $ 1,474 2.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 30,714 kWh $ 1,474 $ 0.051 /kWh

TOTAL ENERGY

 315 MMBtu $ 1,474 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 650 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,546 kWh $ 650 $ 0.051 /kWh

TOTAL ENERGY

 139 MMBtu $ 650 -
11 view
details		 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 2.6211 N $ 1 $ 864 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,400 kWh $ 259 $ 0.051 /kWh

- Demand Charge

 54 kW $ 605 $ 11.21 /kW

TOTAL ENERGY

 55 MMBtu $ 864 -
12 view
details		 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 2.8114 N $ 1 $ 18,231 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 18,231 -

TOTAL PRODUCTON

 - $ 18,231 -
13 view
details		 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 2.8114 N $ 1 $ 1,393 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 1,393 -

TOTAL PRODUCTON

 - $ 1,393 -
14 view
details		 MINIMIZE OPERATION OF EQUIPMENT MAINTAINED IN STANDBY CONDITION 2.6242 N $ 7,500 $ 956 7.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 120 MMBtu $ 956 $ 7.97 /MMBtu

TOTAL ENERGY

 120 MMBtu $ 956 -
15 view
details		 MINIMIZE WATER USAGE 3.4151 I $ 15,000 $ 7,267 2.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (non-haz)

 444,600 Gal $ 2,267 $ 0 /Gal

TOTAL WASTE

 - $ 2,267 -

Administrative Changes

 - $ 5,000 -

TOTAL PRODUCTON

 - $ 5,000 -
16 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 1 $ 32 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4 MMBtu $ 32 $ 7.97 /MMBtu

TOTAL ENERGY

 4 MMBtu $ 32 -
17 view
details		 CHANGE PROCEDURES / EQUIPMENT / OPERATING CONDITIONS 3.1191 I $ 15,000 $ 5,723 2.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,922 kWh $ -482 $ 0.051 /kWh

- Demand Charge

 17 kW $ -191 $ 11.21 /kW

TOTAL ENERGY

 91 MMBtu $ -673 -

Personnel Changes

 - $ 3,210 -

Ancillary Material Cost

 - $ 3,186 -

TOTAL PRODUCTON

 - $ 6,396 -
18 view
details		 MODIFY CURRENT INCENTIVE PROGRAM 4.4210 I $ 38,378 $ 19,189 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 230,119 kWh $ 11,048 $ 0.051 /kWh

- Demand Charge

 574 kW $ 6,435 $ 11.21 /kW

Natural Gas

 175 MMBtu $ 1,395 $ 7.97 /MMBtu

TOTAL ENERGY

 2,534 MMBtu $ 18,878 -

Other Liquid (non-haz)

 61,336 Gal $ 311 $ 0 /Gal

TOTAL WASTE

 - $ 311 -