U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MA0517


Assessment Year 2002
SIC 3052
SIC Description Rubber & Plastics Hose & Belting
NAICS
NAICS Description
Principal Product Teflon and metal hose products
Sales $ 130,000,000
# of Employees 545
Plant Area (Sq.Ft.) 250,000
Annual Production 15,500,000 Pounds
Production Hrs. Annual 6,552
Location (State) MA
Yearly Energy Cost $ 1,569,957

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 14,199,135 kWh $ 680,219 $ 0.048 /kWh

- Demand Charge

 26,202 kW $ 354,580 $ 13.53 /kW

- Electricity Fees

 - $ 174,113 -

Natural Gas

 32,079 MMBtu $ 210,373 $ 6.56 /MMBtu

Fuel Oil #2

 1,496 MMBtu $ 11,794 $ 7.88 /MMBtu

Fuel Oil #4

 27,933 MMBtu $ 138,878 $ 4.97 /MMBtu

TOTAL ENERGY

 207,049 MMBtu $ 1,569,957 $ 7.58 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 666,503 kWh
238,441 kWh		 $ 32,426
$ 11,252		 4.77 %
1.65 %		 $ 0.048 /kWh

- Demand Charge

 0 kW
0 kW		 $ 0
$ 0		 0.00 %
0.00 %		 $ 13.53 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 4,481 MMBtu
4,481 MMBtu		 $ 36,456
$ 36,456		 17.33 %
17.33 %		 $ 6.56 /MMBtu

Fuel Oil #2

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 7.88 /MMBtu

Fuel Oil #4

 -2,078 MMBtu
71 MMBtu		 $ -9,145
$ 332		 -6.58 %
0.24 %		 $ 4.97 /MMBtu

TOTAL ENERGY

 9,236 MMBtu
6,997 MMBtu		 $ 59,737
$ 48,040		 3.81 %
3.06 %		 $ 7.58 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 COVER OPEN TANKS WITH FLOATING INSULATION 2.2513 I $ 4,262 $ 30,107 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,702 MMBtu $ 30,107 $ 6.56 /MMBtu

TOTAL ENERGY

 3,702 MMBtu $ 30,107 -
02 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 33,800 $ 11,697 2.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 428,062 kWh $ 21,174 $ 0.048 /kWh

Fuel Oil #4

 -2,149 MMBtu $ -9,477 $ 4.97 /MMBtu

TOTAL ENERGY

 2,239 MMBtu $ 11,697 -
03 view
details		 USE MINIMUM SAFE OVEN VENTILATION 2.2212 I $ 2,100 $ 7,427 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 147,325 kWh $ 7,095 $ 0.048 /kWh

Fuel Oil #4

 71 MMBtu $ 332 $ 4.97 /MMBtu

TOTAL ENERGY

 1,581 MMBtu $ 7,427 -
04 view
details		 PAY BILLS ON TIME TO AVOID LATE FEES 4.8210 I $ 0 $ 6,528 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

One-time Revenue or Avoided Cost

 - $ 6,528 -

TOTAL PRODUCTON

 - $ 6,528 -
05 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 9,636 $ 6,349 1.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 779 MMBtu $ 6,349 $ 6.56 /MMBtu

TOTAL ENERGY

 779 MMBtu $ 6,349 -
06 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 5,200 $ 2,140 2.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,274 kWh $ 2,140 $ 0.048 /kWh

TOTAL ENERGY

 444 MMBtu $ 2,140 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 2,500 $ 1,164 2.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,151 kWh $ 1,164 $ 0.048 /kWh

TOTAL ENERGY

 289 MMBtu $ 1,164 -
08 view
details		 MINIMIZE OPERATION OF EQUIPMENT MAINTAINED IN STANDBY CONDITION 2.6242 I $ 1,515 $ 853 1.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,691 kWh $ 853 $ 0.048 /kWh

TOTAL ENERGY

 202 MMBtu $ 853 -