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

Industrial Assessment Centers

Assessment #IC0182


Assessment Year 2011
SIC 2821
SIC Description Plastics Materials And Resins
NAICS 325211
NAICS Description Plastics Material and Resin Manufacturing
Principal Product Coating and Resins
Sales $ 31,000,000
# of Employees 32
Plant Area (Sq.Ft.) 102,732
Annual Production 25,000,000 Pounds
Production Hrs. Annual 5,832
Location (State) WI
Yearly Energy Cost $ 537,972

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,364,284 kWh $ 169,074 $ 0.050 /kWh

- Demand Charge

 6,348 kW $ 69,058 $ 10.88 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 52,435 MMBtu $ 299,840 $ 5.72 /MMBtu

TOTAL ENERGY

 86,919 MMBtu $ 537,972 $ 6.19 /MMBtu

Water Disposal

 9,882,000 Gal $ 63,210 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 313,363 kWh
0 kWh		 $ 15,667
$ 0		 9.27 %
0.00 %		 $ 0.050 /kWh

- Demand Charge

 797 kW
0 kW		 $ 8,530
$ 0		 12.35 %
0.00 %		 $ 10.88 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,259 MMBtu
0 MMBtu		 $ 12,923
$ 0		 4.31 %
0.00 %		 $ 5.72 /MMBtu

TOTAL ENERGY

 5,471 MMBtu
0 MMBtu		 $ 37,120
$ 0		 6.90 %
0.00 %		 $ 6.19 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 116 $ 75 1.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 315 kWh $ 16 $ 0.050 /kWh

- Demand Charge

 0 kW $ 5 $ 10.88 /kW

TOTAL ENERGY

 3 MMBtu $ 21 -

One-time Revenue or Avoided Cost

 - $ 54 -

TOTAL PRODUCTON

 - $ 54 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 672 $ 2,306 0.29
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,195 kWh $ 959 $ 0.050 /kWh

- Demand Charge

 88 kW $ 961 $ 10.88 /kW

TOTAL ENERGY

 197 MMBtu $ 1,920 -

One-time Revenue or Avoided Cost

 - $ 386 -

TOTAL PRODUCTON

 - $ 386 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 0 $ 273 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,716 kWh $ 137 $ 0.050 /kWh

- Demand Charge

 16 kW $ 169 $ 10.88 /kW

TOTAL ENERGY

 28 MMBtu $ 306 -

Ancillary Material Cost

 - $ -33 -

TOTAL PRODUCTON

 - $ -33 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 43,859 $ 9,045 4.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 133,590 kWh $ 6,680 $ 0.050 /kWh

- Demand Charge

 183 kW $ 1,991 $ 10.88 /kW

TOTAL ENERGY

 1,369 MMBtu $ 8,671 -

One-time Revenue or Avoided Cost

 - $ 374 -

TOTAL PRODUCTON

 - $ 374 -
05 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 N $ 11,001 $ 2,734 4.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,116 kWh $ 2,106 $ 0.050 /kWh

- Demand Charge

 58 kW $ 628 $ 10.88 /kW

TOTAL ENERGY

 432 MMBtu $ 2,734 -
06 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 N $ 0 $ 3,070 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,713 kWh $ 2,284 $ 0.050 /kWh

- Demand Charge

 72 kW $ 786 $ 10.88 /kW

TOTAL ENERGY

 469 MMBtu $ 3,070 -
07 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 5,489 $ 4,314 1.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 754 MMBtu $ 4,314 $ 5.72 /MMBtu

TOTAL ENERGY

 754 MMBtu $ 4,314 -
08 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 311 $ 950 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 166 MMBtu $ 950 $ 5.72 /MMBtu

TOTAL ENERGY

 166 MMBtu $ 950 -
09 view
details		 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 2.1113 N $ 311 $ 2,442 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 427 MMBtu $ 2,442 $ 5.72 /MMBtu

TOTAL ENERGY

 427 MMBtu $ 2,442 -
10 view
details		 INSTALL AUTOMATIC STACK DAMPER 2.1123 N $ 50,324 $ 5,217 9.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 912 MMBtu $ 5,217 $ 5.72 /MMBtu

TOTAL ENERGY

 912 MMBtu $ 5,217 -
11 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 921 $ 2,294 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,344 kWh $ 1,767 $ 0.050 /kWh

- Demand Charge

 48 kW $ 527 $ 10.88 /kW

TOTAL ENERGY

 362 MMBtu $ 2,294 -
12 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 N $ 1,318 $ 1,314 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,280 kWh $ 1,314 $ 0.050 /kWh

TOTAL ENERGY

 269 MMBtu $ 1,314 -
13 view
details		 MINIMIZE OPERATION OF EQUIPMENT MAINTAINED IN STANDBY CONDITION 2.6242 N $ 379 $ 379 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,394 kWh $ 319 $ 0.050 /kWh

- Demand Charge

 6 kW $ 60 $ 10.88 /kW

TOTAL ENERGY

 66 MMBtu $ 379 -
14 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 20,932 $ 3,378 6.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 323 kW $ 3,378 $ 10.88 /kW

TOTAL ENERGY

 0 MMBtu $ 3,378 -
15 view
details		 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 2.6211 N $ 0 $ 110 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,700 kWh $ 85 $ 0.050 /kWh

- Demand Charge

 2 kW $ 25 $ 10.88 /kW

TOTAL ENERGY

 17 MMBtu $ 110 -