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

Industrial Assessment Centers

Assessment #MA0609


Assessment Year 2007
SIC 3497
SIC Description Metal Foil And Leaf
NAICS 326113
NAICS Description Unlaminated Plastics Film and Sheet (except Packaging) Manufacturing
Principal Product Slit plastic and paper films, cable fillers, non-woven films
Sales $ 13,000,000
# of Employees 54
Plant Area (Sq.Ft.) 52,200
Annual Production 1,250,000 Pounds
Production Hrs. Annual 6,240
Location (State) CT
Yearly Energy Cost $ 443,620

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,816,964 kWh $ 333,043 $ 0.087 /kWh

- Demand Charge

 8,417 kW $ 79,378 $ 9.43 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 2,399 MMBtu $ 31,199 $ 13.01 /MMBtu

TOTAL ENERGY

 41,523 MMBtu $ 443,620 $ 10.68 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 625,000 kWh
0 kWh		 $ 61,876
$ 0		 18.58 %
0.00 %		 $ 0.087 /kWh

- Demand Charge

 2,093 kW
0 kW		 $ 20,334
$ 0		 25.62 %
0.00 %		 $ 9.43 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -543 MMBtu
0 MMBtu		 $ -6,359
$ 0		 -20.38 %
0.00 %		 $ 13.01 /MMBtu

TOTAL ENERGY

 5,862 MMBtu
0 MMBtu		 $ 75,851
$ 0		 17.10 %
0.00 %		 $ 10.68 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 54,000 $ 45,854 1.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 513,000 kWh $ 50,787 $ 0.087 /kWh

- Demand Charge

 1,972 kW $ 19,166 $ 9.43 /kW

Natural Gas

 -2,058 MMBtu $ -24,099 $ 13.01 /MMBtu

TOTAL ENERGY

 3,200 MMBtu $ 45,854 -
02 view
details		 USE "HEAT WHEEL" OR OTHER HEAT EXCHANGER TO CROSS-EXCHANGE BUILDING EXHAUST AIR WITH MAKE-UP AIR 2.2492 N $ 40,000 $ 11,356 3.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -18,000 kWh $ -1,782 $ 0.087 /kWh

- Demand Charge

 -35 kW $ -340 $ 9.43 /kW

Natural Gas

 1,151 MMBtu $ 13,478 $ 13.01 /MMBtu

TOTAL ENERGY

 966 MMBtu $ 11,356 -
03 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 5,000 $ 5,050 0.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,800 kWh $ 1,960 $ 0.087 /kWh

- Demand Charge

 36 kW $ 350 $ 9.43 /kW

Natural Gas

 234 MMBtu $ 2,740 $ 13.01 /MMBtu

TOTAL ENERGY

 437 MMBtu $ 5,050 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 19,100 $ 4,398 4.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 40,200 kWh $ 3,980 $ 0.087 /kWh

- Demand Charge

 43 kW $ 418 $ 9.43 /kW

TOTAL ENERGY

 412 MMBtu $ 4,398 -
05 view
details		 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 2.2614 N $ 7,500 $ 3,871 1.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,100 kWh $ 3,871 $ 0.087 /kWh

TOTAL ENERGY

 401 MMBtu $ 3,871 -
06 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 2,200 $ 1,436 1.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,100 kWh $ 901 $ 0.087 /kWh

- Demand Charge

 56 kW $ 535 $ 9.43 /kW

TOTAL ENERGY

 93 MMBtu $ 1,436 -
07 view
details		 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 2.7243 N $ 3,200 $ 1,227 2.61
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -2,600 kWh $ -257 $ 0.087 /kWh

- Demand Charge

 -4 kW $ -38 $ 9.43 /kW

Natural Gas

 130 MMBtu $ 1,522 $ 13.01 /MMBtu

TOTAL ENERGY

 103 MMBtu $ 1,227 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 300 $ 1,158 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,700 kWh $ 1,158 $ 0.087 /kWh

TOTAL ENERGY

 120 MMBtu $ 1,158 -
09 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 600 $ 849 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,200 kWh $ 713 $ 0.087 /kWh

- Demand Charge

 14 kW $ 136 $ 9.43 /kW

TOTAL ENERGY

 74 MMBtu $ 849 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 652 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,500 kWh $ 545 $ 0.087 /kWh

- Demand Charge

 11 kW $ 107 $ 9.43 /kW

TOTAL ENERGY

 56 MMBtu $ 652 -