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

Industrial Assessment Centers

Assessment #KU0390


Assessment Year 1992
SIC 2253
SIC Description Knit Outerwear Mills
NAICS
NAICS Description
Principal Product T-SHIRTS
Sales $ 27,000,000
# of Employees 615
Plant Area (Sq.Ft.) 0
Annual Production 700,000 Pieces
Production Hrs. Annual 8,592
Location (State) KS
Yearly Energy Cost $ 275,361

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,291,618 kWh $ 275,361 $ 0.084 /kWh

- Electricity Fees

 - $ 0 -

TOTAL ENERGY

 33,739 MMBtu $ 275,361 $ 8.16 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,451,640 kWh
19,929 kWh		 $ 285,638
$ 1,667		 103.73 %
0.61 %		 $ 0.084 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

TOTAL ENERGY

 32,241 MMBtu
2,417 MMBtu		 $ 282,328
$ 11,682		 102.53 %
4.24 %		 $ 8.16 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 BURN FOSSIL FUEL TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR AND USE STEAM EXHAUST FOR HEAT 2.3413 N $ 0 $ 180,344 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,308,910 kWh $ 276,830 $ 0.084 /kWh

Natural Gas

 -18,816 MMBtu $ -46,852 $ 0.00 /MMBtu

TOTAL ENERGY

 15,100 MMBtu $ 229,978 -

Administrative Changes

 - $ -49,634 -

TOTAL PRODUCTON

 - $ -49,634 -
02 view
details		 RECOVER HEAT FROM HOT WASTE WATER 2.2446 N $ 10,200 $ 20,311 0.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 8,157 MMBtu $ 20,311 $ 0.00 /MMBtu

TOTAL ENERGY

 8,157 MMBtu $ 20,311 -
03 view
details		 USE STEAM SPARGING OR INJECTIONS IN PLACE OF INDIRECT HEATING 2.1393 N $ 9,570 $ 8,568 1.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,441 MMBtu $ 8,568 $ 0.00 /MMBtu

TOTAL ENERGY

 3,441 MMBtu $ 8,568 -
04 view
details		 BURN A LESS EXPENSIVE GRADE OF FUEL 2.1331 I $ 0 $ 4,504 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 -2,233 MMBtu $ -5,560 $ 0.00 /MMBtu

LPG

 2,233 MMBtu $ 10,064 $ 0.00 /MMBtu

TOTAL ENERGY

 0 MMBtu $ 4,504 -
05 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 I $ 3,800 $ 3,643 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,463 MMBtu $ 3,643 $ 0.00 /MMBtu

TOTAL ENERGY

 1,463 MMBtu $ 3,643 -
06 view
details		 USE HOT PROCESS FLUIDS TO PREHEAT INCOMING PROCESS FLUIDS 2.2444 N $ 5,600 $ 3,635 1.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,460 MMBtu $ 3,635 $ 0.00 /MMBtu

TOTAL ENERGY

 1,460 MMBtu $ 3,635 -
07 view
details		 INSTALL SET-BACK TIMERS 2.6232 N $ 1,000 $ 3,237 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 38,687 kWh $ 3,237 $ 0.084 /kWh

TOTAL ENERGY

 397 MMBtu $ 3,237 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 0 $ 1,430 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,050 kWh $ 1,588 $ 0.084 /kWh

TOTAL ENERGY

 195 MMBtu $ 1,588 -

Administrative Changes

 - $ -158 -

TOTAL PRODUCTON

 - $ -158 -
09 view
details		 INSTALL SET-BACK TIMERS 2.6232 N $ 285 $ 1,251 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,947 kWh $ 1,251 $ 0.084 /kWh

TOTAL ENERGY

 153 MMBtu $ 1,251 -
10 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 891 $ 711 1.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,499 kWh $ 711 $ 0.084 /kWh

TOTAL ENERGY

 87 MMBtu $ 711 -
11 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 420 $ 1,839 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,981 kWh $ 1,839 $ 0.084 /kWh

TOTAL ENERGY

 225 MMBtu $ 1,839 -
12 view
details		 USE FLUE GASES IN RADIANT HEATER FOR SPACE HEATING, OVENS, ETC 2.2428 I $ 1,250 $ 1,696 0.74
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -2,052 kWh $ -172 $ 0.084 /kWh

Natural Gas

 750 MMBtu $ 1,868 $ 0.00 /MMBtu

TOTAL ENERGY

 729 MMBtu $ 1,696 -
13 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 N $ 2,973 $ 1,013 2.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 407 MMBtu $ 1,013 $ 0.00 /MMBtu

TOTAL ENERGY

 407 MMBtu $ 1,013 -
14 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 406 $ 354 1.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 41,618 kWh $ 354 $ 0.084 /kWh

TOTAL ENERGY

 427 MMBtu $ 354 -