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

Industrial Assessment Centers

Assessment #LE0303


Assessment Year 2010
SIC 2653
SIC Description Corrugated And Solid Fiber Boxes
NAICS 322211
NAICS Description Corrugated and Solid Fiber Box Manufacturing
Principal Product secondary co-packer
Sales $ 81,000,000
# of Employees 200
Plant Area (Sq.Ft.) 124,000
Annual Production 1,000 Not Available
Production Hrs. Annual 4,160
Location (State) PA
Yearly Energy Cost $ 161,730

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,120,000 kWh $ 80,178 $ 0.072 /kWh

- Demand Charge

 3,187 kW $ 27,430 $ 8.61 /kW

- Electricity Fees

 - $ 0 -

Other Gas

 2,429 MMBtu $ 54,122 $ 22.28 /MMBtu

TOTAL ENERGY

 13,909 MMBtu $ 161,730 $ 11.63 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 597,595 kWh
454,200 kWh		 $ 43,026
$ 32,701		 53.66 %
40.79 %		 $ 0.072 /kWh

- Demand Charge

 1,117 kW
772 kW		 $ 9,620
$ 6,649		 35.07 %
24.24 %		 $ 8.61 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Other Gas

 165 MMBtu
44 MMBtu		 $ 3,678
$ 973		 6.80 %
1.80 %		 $ 22.28 /MMBtu

TOTAL ENERGY

 6,292 MMBtu
4,700 MMBtu		 $ 56,324
$ 40,323		 34.83 %
24.93 %		 $ 11.63 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,672 $ 26,348 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 278,206 kWh $ 20,029 $ 0.072 /kWh

- Demand Charge

 734 kW $ 6,319 $ 8.61 /kW

TOTAL ENERGY

 2,852 MMBtu $ 26,348 -
02 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 I $ 650 $ 10,520 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 146,105 kWh $ 10,520 $ 0.072 /kWh

TOTAL ENERGY

 1,498 MMBtu $ 10,520 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET 2.4142 N $ 1,500 $ 4,909 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 52,511 kWh $ 3,781 $ 0.072 /kWh

- Demand Charge

 131 kW $ 1,128 $ 8.61 /kW

TOTAL ENERGY

 538 MMBtu $ 4,909 -
04 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 2,200 $ 3,385 0.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,010 kWh $ 3,385 $ 0.072 /kWh

TOTAL ENERGY

 482 MMBtu $ 3,385 -
05 view
details		 MINIMIZE USE OF OUTSIDE MAKE-UP AIR FOR VENTILATION EXCEPT WHEN USED FOR ECONOMIZER CYCLE 2.7312 N $ 7,000 $ 2,574 2.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -1,820 kWh $ -131 $ 0.072 /kWh

Other Gas

 121 MMBtu $ 2,705 $ 22.28 /MMBtu

TOTAL ENERGY

 103 MMBtu $ 2,574 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 25,900 $ 1,931 13.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,365 kWh $ 1,466 $ 0.072 /kWh

- Demand Charge

 54 kW $ 465 $ 8.61 /kW

TOTAL ENERGY

 209 MMBtu $ 1,931 -
07 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 N $ 3,000 $ 1,824 1.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,329 kWh $ 1,824 $ 0.072 /kWh

TOTAL ENERGY

 260 MMBtu $ 1,824 -
08 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 3,000 $ 1,378 2.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 160 kW $ 1,378 $ 8.61 /kW

TOTAL ENERGY

 0 MMBtu $ 1,378 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 800 $ 1,351 0.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,185 kWh $ 1,021 $ 0.072 /kWh

- Demand Charge

 38 kW $ 330 $ 8.61 /kW

TOTAL ENERGY

 145 MMBtu $ 1,351 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 15 $ 1,131 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 15,704 kWh $ 1,131 $ 0.072 /kWh

TOTAL ENERGY

 161 MMBtu $ 1,131 -
11 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 1,000 $ 973 1.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Gas

 44 MMBtu $ 973 $ 22.28 /MMBtu

TOTAL ENERGY

 44 MMBtu $ 973 -