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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MA0683


Assessment Year 2011
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Extruded and coated film
Sales $ 75,000,000
# of Employees 105
Plant Area (Sq.Ft.) 85,000
Annual Production 4,000,000 Pounds
Production Hrs. Annual 6,240
Location (State) MA
Yearly Energy Cost $ 602,686

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,085,550 kWh $ 414,819 $ 0.102 /kWh

- Demand Charge

 11,879 kW $ 46,565 $ 3.92 /kW

- Electricity Fees

 - $ 2,400 -

Natural Gas

 16,919 MMBtu $ 138,902 $ 8.21 /MMBtu

TOTAL ENERGY

 58,796 MMBtu $ 602,686 $ 10.25 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 139,304 kWh
139,304 kWh		 $ 14,137
$ 14,137		 3.41 %
3.41 %		 $ 0.102 /kWh

- Demand Charge

 0 kW
0 kW		 $ 0
$ 0		 0.00 %
0.00 %		 $ 3.92 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 3,198 MMBtu
192 MMBtu		 $ 26,256
$ 1,577		 18.90 %
1.14 %		 $ 8.21 /MMBtu

TOTAL ENERGY

 4,626 MMBtu
1,620 MMBtu		 $ 40,393
$ 15,714		 6.70 %
2.61 %		 $ 10.25 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 2.1113 N $ 50,000 $ 24,679 2.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,006 MMBtu $ 24,679 $ 8.21 /MMBtu

TOTAL ENERGY

 3,006 MMBtu $ 24,679 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 2,800 $ 12,021 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 118,441 kWh $ 12,021 $ 0.102 /kWh

TOTAL ENERGY

 1,214 MMBtu $ 12,021 -
03 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 200 $ 1,273 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 155 MMBtu $ 1,273 $ 8.21 /MMBtu

TOTAL ENERGY

 155 MMBtu $ 1,273 -
04 view
details		 VENTILATION SYSTEM TO SHUT OFF WHEN ROOM IS NOT IN USE 2.7311 I $ 200 $ 1,113 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,978 kWh $ 809 $ 0.102 /kWh

Natural Gas

 37 MMBtu $ 304 $ 8.21 /MMBtu

TOTAL ENERGY

 119 MMBtu $ 1,113 -
05 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 200 $ 821 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,093 kWh $ 821 $ 0.102 /kWh

TOTAL ENERGY

 83 MMBtu $ 821 -
06 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 100 $ 486 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,792 kWh $ 486 $ 0.102 /kWh

TOTAL ENERGY

 49 MMBtu $ 486 -