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

Industrial Assessment Centers

Assessment #LE0217


Assessment Year 2005
SIC 3087
SIC Description Custom Compound Purchased Resins
NAICS 325991
NAICS Description Custom Compounding of Purchased Resins
Principal Product Extruded Plastic Pellets
Sales $ 9,100,000
# of Employees 30
Plant Area (Sq.Ft.) 175,000
Annual Production 2,700 Tons
Production Hrs. Annual 6,240
Location (State) DE
Yearly Energy Cost $ 245,530

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,122,400 kWh $ 152,771 $ 0.049 /kWh

- Demand Charge

 8,586 kW $ 92,759 $ 10.80 /kW

- Electricity Fees

 - $ 0 -

TOTAL ENERGY

 32,005 MMBtu $ 245,530 $ 7.67 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,205,973 kWh
412,682 kWh		 $ 59,092
$ 20,221		 38.68 %
13.24 %		 $ 0.049 /kWh

- Demand Charge

 749 kW
237 kW		 $ 8,092
$ 2,560		 8.72 %
2.76 %		 $ 10.80 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

TOTAL ENERGY

 12,361 MMBtu
4,230 MMBtu		 $ 67,184
$ 22,781		 27.36 %
9.28 %		 $ 7.67 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 27,000 $ 33,752 0.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 688,816 kWh $ 33,752 $ 0.049 /kWh

TOTAL ENERGY

 7,060 MMBtu $ 33,752 -
02 view
details		 KEEP EQUIPMENT CLEAN 2.6125 I $ 840 $ 28,000 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Increase in Production

 - $ 28,000 -

TOTAL PRODUCTON

 - $ 28,000 -
03 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 6,845 $ 16,487 0.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 336,469 kWh $ 16,487 $ 0.049 /kWh

TOTAL ENERGY

 3,449 MMBtu $ 16,487 -
04 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 3,000 $ 5,186 0.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 480 kW $ 5,186 $ 10.80 /kW

TOTAL ENERGY

 0 MMBtu $ 5,186 -
05 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 N $ 4,000 $ 3,202 1.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 65,344 kWh $ 3,202 $ 0.049 /kWh

TOTAL ENERGY

 670 MMBtu $ 3,202 -
06 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 900 $ 2,764 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 56,398 kWh $ 2,764 $ 0.049 /kWh

TOTAL ENERGY

 578 MMBtu $ 2,764 -
07 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 900 $ 2,158 0.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 159 kWh $ 7 $ 0.049 /kWh

- Demand Charge

 199 kW $ 2,151 $ 10.80 /kW

TOTAL ENERGY

 2 MMBtu $ 2,158 -
08 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 I $ 263 $ 1,372 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,656 kWh $ 963 $ 0.049 /kWh

- Demand Charge

 38 kW $ 409 $ 10.80 /kW

TOTAL ENERGY

 201 MMBtu $ 1,372 -
09 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 240 $ 1,389 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,288 kWh $ 1,043 $ 0.049 /kWh

- Demand Charge

 32 kW $ 346 $ 10.80 /kW

TOTAL ENERGY

 218 MMBtu $ 1,389 -
10 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 150 $ 874 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,843 kWh $ 874 $ 0.049 /kWh

TOTAL ENERGY

 183 MMBtu $ 874 -