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

Industrial Assessment Centers

Assessment #LE0293


Assessment Year 2009
SIC 3291
SIC Description Abrasive Products
NAICS 327910
NAICS Description Abrasive Product Manufacturing
Principal Product Industrial wire brushes
Sales $ 65,000,000
# of Employees 362
Plant Area (Sq.Ft.) 220,500
Annual Production 1,000,000 Not Available
Production Hrs. Annual 6,240
Location (State) PA
Yearly Energy Cost $ 414,863

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,688,400 kWh $ 220,203 $ 0.047 /kWh

- Demand Charge

 10,556 kW $ 92,154 $ 8.73 /kW

- Electricity Fees

 - $ 0 -

Fuel Oil #4

 3,953 MMBtu $ 102,506 $ 25.93 /MMBtu

TOTAL ENERGY

 52,009 MMBtu $ 414,863 $ 7.98 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 603,990 kWh
596,415 kWh		 $ 31,577
$ 31,221		 14.34 %
14.18 %		 $ 0.047 /kWh

- Demand Charge

 1,521 kW
1,521 kW		 $ 11,441
$ 11,441		 12.42 %
12.42 %		 $ 8.73 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Fuel Oil #4

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 25.93 /MMBtu

TOTAL ENERGY

 6,765 MMBtu
6,687 MMBtu		 $ 57,876
$ 57,520		 13.95 %
13.86 %		 $ 7.98 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE BATCH FIRING WITH KILN "FURNITURE" SPECIFICALLY DESIGNED 2.2313 I $ 15,000 $ 25,144 0.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 167,887 kWh $ 7,890 $ 0.047 /kWh

- Demand Charge

 573 kW $ 2,396 $ 8.73 /kW

Fuel Oil #2

 573 MMBtu $ 14,858 $ 0.00 /MMBtu

TOTAL ENERGY

 2,294 MMBtu $ 25,144 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,800 $ 9,797 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 101,744 kWh $ 7,249 $ 0.047 /kWh

- Demand Charge

 196 kW $ 2,548 $ 8.73 /kW

TOTAL ENERGY

 1,043 MMBtu $ 9,797 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 I $ 2,932 $ 4,105 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 68,331 kWh $ 2,874 $ 0.047 /kWh

- Demand Charge

 141 kW $ 1,231 $ 8.73 /kW

TOTAL ENERGY

 700 MMBtu $ 4,105 -
04 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 700 $ 2,864 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 60,937 kWh $ 2,864 $ 0.047 /kWh

TOTAL ENERGY

 625 MMBtu $ 2,864 -
05 view
details		 INSTALL SOFT-START TO ELIMINATE NUISANCE TRIPS 2.4112 I $ 27,600 $ 1,697 16.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 194 kW $ 1,697 $ 8.73 /kW

TOTAL ENERGY

 0 MMBtu $ 1,697 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 1,675 $ 717 2.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,429 kWh $ 528 $ 0.047 /kWh

- Demand Charge

 30 kW $ 189 $ 8.73 /kW

TOTAL ENERGY

 138 MMBtu $ 717 -
07 view
details		 MINIMIZE USE OF OUTSIDE MAKE-UP AIR FOR VENTILATION EXCEPT WHEN USED FOR ECONOMIZER CYCLE 2.7312 N $ 2,250 $ 356 6.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,575 kWh $ 356 $ 0.047 /kWh

TOTAL ENERGY

 78 MMBtu $ 356 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 58,455 $ 13,196 4.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 184,087 kWh $ 9,816 $ 0.047 /kWh

- Demand Charge

 387 kW $ 3,380 $ 8.73 /kW

TOTAL ENERGY

 1,887 MMBtu $ 13,196 -