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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MS0273


Assessment Year 2005
SIC 2841
SIC Description Soap And Other Detergents
NAICS 325611
NAICS Description Soap and Other Detergent Manufacturing
Principal Product Soap
Sales $ 25,000,000
# of Employees 126
Plant Area (Sq.Ft.) 200,000
Annual Production 75,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) TN
Yearly Energy Cost $ 795,938

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,425,600 kWh $ 182,397 $ 0.041 /kWh

- Demand Charge

 12,364 kW $ 113,573 $ 9.19 /kW

- Electricity Fees

 - $ 8,505 -

Natural Gas

 67,852 MMBtu $ 491,463 $ 7.24 /MMBtu

TOTAL ENERGY

 113,214 MMBtu $ 795,938 $ 7.03 /MMBtu

Water Disposal

 17,652 Gal $ 14,640 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 539,926 kWh
0 kWh		 $ 18,891
$ 0		 10.36 %
0.00 %		 $ 0.041 /kWh

- Demand Charge

 680 kW
0 kW		 $ 7,372
$ 0		 6.49 %
0.00 %		 $ 9.19 /kW

- Electricity Fees

 - $ 394
$ 0		 4.63 %
0.00 %		 -

Natural Gas

 4,051 MMBtu
1,092 MMBtu		 $ 29,565
$ 7,759		 6.02 %
1.58 %		 $ 7.24 /MMBtu

TOTAL ENERGY

 9,585 MMBtu
1,092 MMBtu		 $ 56,222
$ 7,759		 7.06 %
0.97 %		 $ 7.03 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 12,540 $ 16,069 0.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,275 MMBtu $ 16,069 $ 7.24 /MMBtu

TOTAL ENERGY

 2,275 MMBtu $ 16,069 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 26,912 $ 10,056 2.68
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 182,462 kWh $ 6,384 $ 0.041 /kWh

- Demand Charge

 325 kW $ 3,523 $ 9.19 /kW

- Electricity Fees

 - $ 149 -

TOTAL ENERGY

 1,870 MMBtu $ 10,056 -
03 view
details		 REPAIR AND ELIMINATE STEAM LEAKS 2.2135 I $ 89 $ 7,498 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,061 MMBtu $ 7,498 $ 7.24 /MMBtu

TOTAL ENERGY

 1,061 MMBtu $ 7,498 -
04 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 685 $ 5,737 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 684 MMBtu $ 5,737 $ 7.24 /MMBtu

TOTAL ENERGY

 684 MMBtu $ 5,737 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 19,601 $ 5,326 3.68
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 83,987 kWh $ 2,939 $ 0.041 /kWh

- Demand Charge

 213 kW $ 2,309 $ 9.19 /kW

- Electricity Fees

 - $ 78 -

TOTAL ENERGY

 861 MMBtu $ 5,326 -
06 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 1,480 $ 4,219 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 118,790 kWh $ 4,156 $ 0.041 /kWh

- Electricity Fees

 - $ 63 -

TOTAL ENERGY

 1,218 MMBtu $ 4,219 -
07 view
details		 PAY UTILITY BILLS ON TIME 2.8123 I $ 0 $ 3,704 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 3,704 -

TOTAL PRODUCTON

 - $ 3,704 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 203 $ 2,474 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,656 kWh $ 2,437 $ 0.041 /kWh

- Electricity Fees

 - $ 37 -

TOTAL ENERGY

 714 MMBtu $ 2,474 -
09 view
details		 USE SEPARATE SWITCHES ON PERIMETER LIGHTING WHICH MAY BE TURNED OFF WHEN NATURAL LIGHT IS AVAILABLE 2.7133 N $ 231 $ 2,353 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 38,375 kWh $ 1,343 $ 0.041 /kWh

- Demand Charge

 90 kW $ 976 $ 9.19 /kW

- Electricity Fees

 - $ 34 -

TOTAL ENERGY

 393 MMBtu $ 2,353 -
10 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 N $ 1,215 $ 1,338 0.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 37,670 kWh $ 1,318 $ 0.041 /kWh

- Electricity Fees

 - $ 20 -

TOTAL ENERGY

 386 MMBtu $ 1,338 -
11 view
details		 CONDITION SMALLEST SPACE NECESSARY 2.7223 N $ 240 $ 891 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,986 kWh $ 314 $ 0.041 /kWh

- Demand Charge

 52 kW $ 564 $ 9.19 /kW

- Electricity Fees

 - $ 13 -

TOTAL ENERGY

 92 MMBtu $ 891 -
12 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 I $ 204 $ 261 0.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 31 MMBtu $ 261 $ 7.24 /MMBtu

TOTAL ENERGY

 31 MMBtu $ 261 -