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

Industrial Assessment Centers

Assessment #KU0446


Assessment Year 1994
SIC 3621
SIC Description Motors And Generators
NAICS
NAICS Description
Principal Product diesel generators
Sales $ 6,000,000
# of Employees 430
Plant Area (Sq.Ft.) 160,125
Annual Production 5,500 Pieces
Production Hrs. Annual 2,340
Location (State) MO
Yearly Energy Cost $ 228,237

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,418,816 kWh $ 169,404 $ 0.070 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 11,410 MMBtu $ 58,833 $ 5.16 /MMBtu

TOTAL ENERGY

 36,203 MMBtu $ 228,237 $ 6.30 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 793,961 kWh
245,897 kWh		 $ 57,297
$ 18,907		 33.82 %
11.16 %		 $ 0.070 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -1,460 MMBtu
42 MMBtu		 $ -7,533
$ 217		 -12.80 %
0.37 %		 $ 5.16 /MMBtu

TOTAL ENERGY

 6,677 MMBtu
2,562 MMBtu		 $ 49,764
$ 19,124		 21.80 %
8.38 %		 $ 6.30 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 CONVERT TO ELECTROSTATIC POWDER COATING 3.2121 N $ 12,000 $ 38,324 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 96,131 kWh $ 6,734 $ 0.070 /kWh

TOTAL ENERGY

 985 MMBtu $ 6,734 -

Ancillary Material Cost

 - $ 31,590 -

TOTAL PRODUCTON

 - $ 31,590 -
02 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 2,616 $ 18,466 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 374,267 kWh $ 26,216 $ 0.070 /kWh

Natural Gas

 -1,502 MMBtu $ -7,750 $ 5.16 /MMBtu

TOTAL ENERGY

 2,334 MMBtu $ 18,466 -
03 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 1,600 $ 1,601 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,860 kWh $ 1,601 $ 0.070 /kWh

TOTAL ENERGY

 234 MMBtu $ 1,601 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 300 $ 4,291 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 61,254 kWh $ 4,291 $ 0.070 /kWh

TOTAL ENERGY

 628 MMBtu $ 4,291 -
05 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 10 $ 3,038 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,376 kWh $ 3,038 $ 0.070 /kWh

TOTAL ENERGY

 445 MMBtu $ 3,038 -
06 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 240 $ 2,279 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 32,532 kWh $ 2,279 $ 0.070 /kWh

TOTAL ENERGY

 333 MMBtu $ 2,279 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 150 $ 801 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,430 kWh $ 801 $ 0.070 /kWh

TOTAL ENERGY

 117 MMBtu $ 801 -
08 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 1,197 $ 965 1.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,775 kWh $ 965 $ 0.070 /kWh

TOTAL ENERGY

 141 MMBtu $ 965 -
09 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 191 $ 698 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,965 kWh $ 698 $ 0.070 /kWh

TOTAL ENERGY

 102 MMBtu $ 698 -
10 view
details		 REDUCE HOT WATER TEMPERATURE TO THE MINIMUM REQUIRED 2.6121 I $ 10 $ 504 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,103 kWh $ 287 $ 0.070 /kWh

Natural Gas

 42 MMBtu $ 217 $ 5.16 /MMBtu

TOTAL ENERGY

 84 MMBtu $ 504 -
11 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 12,960 $ 5,584 2.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,617 kWh $ 5,584 $ 0.070 /kWh

TOTAL ENERGY

 601 MMBtu $ 5,584 -
12 view
details		 INSTALL SKYLIGHTS 2.7145 I $ 4,920 $ 3,223 1.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 46,014 kWh $ 3,223 $ 0.070 /kWh

TOTAL ENERGY

 472 MMBtu $ 3,223 -
13 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 1,540 $ 1,170 1.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,706 kWh $ 1,170 $ 0.070 /kWh

TOTAL ENERGY

 171 MMBtu $ 1,170 -
14 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 540 $ 410 1.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,931 kWh $ 410 $ 0.070 /kWh

TOTAL ENERGY

 30 MMBtu $ 410 -