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

Industrial Assessment Centers

Assessment #KU0496


Assessment Year 1998
SIC 3052
SIC Description Rubber & Plastics Hose & Belting
NAICS
NAICS Description
Principal Product rubber hoses and ducts
Sales $ 10,000,000
# of Employees 115
Plant Area (Sq.Ft.) 78,400
Annual Production 504,995 Pounds
Production Hrs. Annual 5,300
Location (State) KS
Yearly Energy Cost $ 133,305

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,576,202 kWh $ 82,223 $ 0.052 /kWh

- Demand Charge

 6,876 kW $ 10,447 $ 1.52 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 8,622 MMBtu $ 40,635 $ 4.71 /MMBtu

TOTAL ENERGY

 24,778 MMBtu $ 133,305 $ 5.38 /MMBtu

Other Liquid (haz)

 17,113 Gal $ 21,935 $ 0 /Gal

Solid Waste (non-haz)

 288,000 lbs $ 5,336 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 596,131 kWh
146,248 kWh		 $ 26,570
$ 7,610		 32.31 %
9.26 %		 $ 0.052 /kWh

- Demand Charge

 1,590 kW
329 kW		 $ 2,410
$ 500		 23.07 %
4.79 %		 $ 1.52 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -148 MMBtu
311 MMBtu		 $ -710
$ 1,460		 -1.75 %
3.59 %		 $ 4.71 /MMBtu

TOTAL ENERGY

 5,962 MMBtu
1,810 MMBtu		 $ 28,270
$ 9,570		 21.21 %
7.18 %		 $ 5.38 /MMBtu

Other Liquid (haz)

 3,360 Gal
0 Gal		 $ 4,260
$ 0		 19.42 %
0.00 %		 $ 0 /Gal

Solid Waste (non-haz)

 0 lbs
0 lbs		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 46,170 $ 12,990 3.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 433,470 kWh $ 18,100 $ 0.052 /kWh

- Demand Charge

 1,224 kW $ 1,860 $ 1.52 /kW

Natural Gas

 -1,479 MMBtu $ -6,970 $ 4.71 /MMBtu

TOTAL ENERGY

 2,964 MMBtu $ 12,990 -
02 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 8,640 $ 3,940 2.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 837 MMBtu $ 3,940 $ 4.71 /MMBtu

TOTAL ENERGY

 837 MMBtu $ 3,940 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 7,290 $ 2,850 2.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 57,444 kWh $ 2,990 $ 0.052 /kWh

- Demand Charge

 137 kW $ 210 $ 1.52 /kW

TOTAL ENERGY

 589 MMBtu $ 3,200 -

Personnel Changes

 - $ -350 -

TOTAL PRODUCTON

 - $ -350 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 600 $ 2,770 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 49,824 kWh $ 2,600 $ 0.052 /kWh

- Demand Charge

 110 kW $ 170 $ 1.52 /kW

TOTAL ENERGY

 511 MMBtu $ 2,770 -
05 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 1,000 $ 1,760 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 260 MMBtu $ 1,220 $ 4.71 /MMBtu

TOTAL ENERGY

 260 MMBtu $ 1,220 -

Personnel Changes

 - $ 540 -

TOTAL PRODUCTON

 - $ 540 -
06 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 2,900 $ 1,350 2.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,326 kWh $ 1,270 $ 0.052 /kWh

- Demand Charge

 55 kW $ 80 $ 1.52 /kW

TOTAL ENERGY

 249 MMBtu $ 1,350 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 720 $ 620 1.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,103 kWh $ 210 $ 0.052 /kWh

- Demand Charge

 6 kW $ 10 $ 1.52 /kW

TOTAL ENERGY

 42 MMBtu $ 220 -

Personnel Changes

 - $ 400 -

TOTAL PRODUCTON

 - $ 400 -
08 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 250 $ 570 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,551 kWh $ 540 $ 0.052 /kWh

- Demand Charge

 21 kW $ 30 $ 1.52 /kW

TOTAL ENERGY

 108 MMBtu $ 570 -
09 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 320 $ 570 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 121 MMBtu $ 570 $ 4.71 /MMBtu

TOTAL ENERGY

 121 MMBtu $ 570 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 250 $ 520 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,379 kWh $ 490 $ 0.052 /kWh

- Demand Charge

 21 kW $ 30 $ 1.52 /kW

TOTAL ENERGY

 96 MMBtu $ 520 -
11 view
details		 USE SYNTHETIC LUBRICANT 2.4314 N $ 610 $ 430 1.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,034 kWh $ 370 $ 0.052 /kWh

- Demand Charge

 16 kW $ 20 $ 1.52 /kW

TOTAL ENERGY

 72 MMBtu $ 390 -

Primary Raw Material

 - $ 40 -

TOTAL PRODUCTON

 - $ 40 -
12 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 440 $ 290 1.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 62 MMBtu $ 290 $ 4.71 /MMBtu

TOTAL ENERGY

 62 MMBtu $ 290 -
13 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 I $ 390 $ 240 1.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 51 MMBtu $ 240 $ 4.71 /MMBtu

TOTAL ENERGY

 51 MMBtu $ 240 -
14 view
details		 USE TIGHT-FITTING LIDS ON MATERIAL CONTAINERS TO REDUCE VOC EMISSIONS 3.8122 N $ 420 $ 4,260 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (haz)

 3,360 Gal $ 4,260 $ 0 /Gal

TOTAL WASTE

 - $ 4,260 -