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

Industrial Assessment Centers

Assessment #MI0223


Assessment Year 2012
SIC 2821
SIC Description Plastics Materials And Resins
NAICS 325211
NAICS Description Plastics Material and Resin Manufacturing
Principal Product Plastic Resins
Sales $ 48,000,000
# of Employees 30
Plant Area (Sq.Ft.) 217,800
Annual Production 42,000,000 Pounds
Production Hrs. Annual 4,992
Location (State) FL
Yearly Energy Cost $ 697,346

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,556,149 kWh $ 269,519 $ 0.076 /kWh

- Demand Charge

 8,703 kW $ 105,828 $ 12.16 /kW

- Electricity Fees

 - $ 33,957 -

Natural Gas

 58,751 MMBtu $ 288,042 $ 4.90 /MMBtu

TOTAL ENERGY

 95,202 MMBtu $ 697,346 $ 7.32 /MMBtu

Other Liquid (haz)

 512,979 Gal $ 181,265 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 916,691 kWh
142,614 kWh		 $ 76,831
$ 12,264		 28.51 %
4.55 %		 $ 0.076 /kWh

- Demand Charge

 2,350 kW
206 kW		 $ 28,594
$ 2,504		 27.02 %
2.37 %		 $ 12.16 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,083 MMBtu
2,083 MMBtu		 $ 10,207
$ 10,207		 3.54 %
3.54 %		 $ 4.90 /MMBtu

TOTAL ENERGY

 11,479 MMBtu
3,545 MMBtu		 $ 115,632
$ 24,975		 16.58 %
3.58 %		 $ 7.32 /MMBtu

Other Liquid (haz)

 153,894 Gal
0 Gal		 $ 5,438
$ 0		 3.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 71,843 $ 40,345 1.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 322,864 kWh $ 27,763 $ 0.076 /kWh

- Demand Charge

 1,033 kW $ 12,582 $ 12.16 /kW

TOTAL ENERGY

 3,309 MMBtu $ 40,345 -
02 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 10,160 $ 26,827 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 232,752 kWh $ 20,017 $ 0.076 /kWh

- Demand Charge

 560 kW $ 6,810 $ 12.16 /kW

TOTAL ENERGY

 2,386 MMBtu $ 26,827 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 14,480 $ 18,776 0.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 162,927 kWh $ 14,012 $ 0.076 /kWh

- Demand Charge

 392 kW $ 4,764 $ 12.16 /kW

TOTAL ENERGY

 1,670 MMBtu $ 18,776 -
04 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 2,520 $ 10,207 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,083 MMBtu $ 10,207 $ 4.90 /MMBtu

TOTAL ENERGY

 2,083 MMBtu $ 10,207 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,660 $ 7,047 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 68,655 kWh $ 5,904 $ 0.076 /kWh

- Demand Charge

 94 kW $ 1,143 $ 12.16 /kW

TOTAL ENERGY

 704 MMBtu $ 7,047 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,510 $ 5,824 0.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 56,697 kWh $ 4,876 $ 0.076 /kWh

- Demand Charge

 78 kW $ 948 $ 12.16 /kW

TOTAL ENERGY

 581 MMBtu $ 5,824 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 1,660 $ 5,438 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (haz)

 153,894 Gal $ 5,438 $ 0 /Gal

TOTAL WASTE

 - $ 5,438 -
08 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 5,920 $ 3,364 1.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 46,551 kWh $ 2,002 $ 0.076 /kWh

- Demand Charge

 112 kW $ 1,362 $ 12.16 /kW

TOTAL ENERGY

 477 MMBtu $ 3,364 -
09 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 N $ 80 $ 1,345 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,983 kWh $ 773 $ 0.076 /kWh

- Demand Charge

 47 kW $ 572 $ 12.16 /kW

TOTAL ENERGY

 92 MMBtu $ 1,345 -
10 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 1,800 $ 1,496 1.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,571 kWh $ 1,253 $ 0.076 /kWh

- Demand Charge

 20 kW $ 243 $ 12.16 /kW

TOTAL ENERGY

 149 MMBtu $ 1,496 -
11 view
details		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 I $ 1,103 $ 401 2.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,691 kWh $ 231 $ 0.076 /kWh

- Demand Charge

 14 kW $ 170 $ 12.16 /kW

TOTAL ENERGY

 28 MMBtu $ 401 -