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

Industrial Assessment Centers

Assessment #LE0238


Assessment Year 2006
SIC 2013
SIC Description Sausages And Other Prepared Meats
NAICS 311613
NAICS Description Rendering and Meat Byproduct Processing
Principal Product collagen casings
Sales $ 40,000,000
# of Employees 220
Plant Area (Sq.Ft.) 145,000
Annual Production 1,214,000 Thousand Feet
Production Hrs. Annual 8,400
Location (State) NJ
Yearly Energy Cost $ 3,027,033

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 14,322,644 kWh $ 1,632,781 $ 0.114 /kWh

- Demand Charge

 23,863 kW $ 111,723 $ 4.68 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 126,243 MMBtu $ 1,282,529 $ 10.16 /MMBtu

TOTAL ENERGY

 273,050 MMBtu $ 3,027,033 $ 11.09 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 9,239,566 kWh
105,193 kWh		 $ 1,178,168
$ 11,993		 72.16 %
0.73 %		 $ 0.114 /kWh

- Demand Charge

 13,870 kW
1,716 kW		 $ 73,432
$ 16,551		 65.73 %
14.81 %		 $ 4.68 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,585 MMBtu
1,585 MMBtu		 $ 240,770
$ 351,913		 18.77 %
27.44 %		 $ 10.16 /MMBtu

TOTAL ENERGY

 96,290 MMBtu
2,663 MMBtu		 $ 1,492,370
$ 380,457		 49.30 %
12.57 %		 $ 11.09 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE SOLAR HEAT TO MAKE ELECTRICTY 2.9114 N $ 2,403,050 $ 1,077,481 2.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 634,522 kWh $ 72,335 $ 0.114 /kWh

TOTAL ENERGY

 6,504 MMBtu $ 72,335 -

One-time Revenue or Avoided Cost

 - $ 1,005,146 -

TOTAL PRODUCTON

 - $ 1,005,146 -
02 view
details		 USE A FOSSIL FUEL ENGINE TO COGENERATE ELECTRICITY OR MOTIVE POWER; AND UTILIZE HEAT 2.3415 N $ 540,000 $ 902,617 0.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,400,000 kWh $ 957,600 $ 0.114 /kWh

- Demand Charge

 12,000 kW $ 56,160 $ 4.68 /kW

Natural Gas

 0 MMBtu $ -111,143 $ 10.16 /MMBtu

TOTAL ENERGY

 86,100 MMBtu $ 902,617 -
03 view
details		 PURCHASE GAS DIRECTLY FROM A CONTRACT GAS SUPPLIER 2.8113 I $ 500 $ 335,810 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 0 MMBtu $ 335,810 $ 10.16 /MMBtu

TOTAL ENERGY

 0 MMBtu $ 335,810 -
04 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 17,600 $ 124,858 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 0 kWh $ 124,858 $ 0.114 /kWh

TOTAL ENERGY

 0 MMBtu $ 124,858 -
05 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 2,500 $ 16,103 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,585 MMBtu $ 16,103 $ 10.16 /MMBtu

TOTAL ENERGY

 1,585 MMBtu $ 16,103 -
06 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 3,000 $ 15,870 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 1,570 kW $ 15,870 $ 4.68 /kW

TOTAL ENERGY

 0 MMBtu $ 15,870 -
07 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 I $ 45,000 $ 9,609 4.68
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 79,791 kWh $ 9,096 $ 0.114 /kWh

- Demand Charge

 110 kW $ 513 $ 4.68 /kW

TOTAL ENERGY

 818 MMBtu $ 9,609 -
08 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 N $ 3,000 $ 5,409 0.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 44,822 kWh $ 5,109 $ 0.114 /kWh

- Demand Charge

 64 kW $ 300 $ 4.68 /kW

TOTAL ENERGY

 459 MMBtu $ 5,409 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 1,000 $ 5,223 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,279 kWh $ 4,933 $ 0.114 /kWh

- Demand Charge

 62 kW $ 290 $ 4.68 /kW

TOTAL ENERGY

 444 MMBtu $ 5,223 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 2,500 $ 1,471 1.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,750 kWh $ 1,340 $ 0.114 /kWh

- Demand Charge

 28 kW $ 131 $ 4.68 /kW

TOTAL ENERGY

 120 MMBtu $ 1,471 -
11 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 I $ 90 $ 3,065 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,402 kWh $ 2,897 $ 0.114 /kWh

- Demand Charge

 36 kW $ 168 $ 4.68 /kW

TOTAL ENERGY

 260 MMBtu $ 3,065 -