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

Industrial Assessment Centers

Assessment #MZ0057


Assessment Year 2010
SIC 3677
SIC Description Electronic Coils And Transformers
NAICS 334416
NAICS Description Electronic Coil, Transformer, and Other Inductor Manufacturing
Principal Product electrical transformers
Sales $ 85,000,000
# of Employees 150
Plant Area (Sq.Ft.) 243,000
Annual Production 350 Pieces
Production Hrs. Annual 7,000
Location (State) MO
Yearly Energy Cost $ 725,395

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,770,492 kWh $ 559,054 $ 0.072 /kWh

- Demand Charge

 12,975 kW $ 22,446 $ 1.73 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 26,947 MMBtu $ 143,895 $ 5.34 /MMBtu

TOTAL ENERGY

 106,595 MMBtu $ 725,395 $ 6.81 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 6,422,912 kWh
4,532,878 kWh		 $ 442,428
$ 310,126		 79.14 %
55.47 %		 $ 0.072 /kWh

- Demand Charge

 11,756 kW
11,702 kW		 $ 21,793
$ 21,699		 97.09 %
96.67 %		 $ 1.73 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 8,686 MMBtu
1,149 MMBtu		 $ 46,248
$ 5,998		 32.14 %
4.17 %		 $ 5.34 /MMBtu

TOTAL ENERGY

 74,522 MMBtu
47,611 MMBtu		 $ 510,469
$ 337,823		 70.37 %
46.57 %		 $ 6.81 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 SHADE WINDOWS FROM SUMMER SUN 2.7424 I $ 46,607 $ 259,173 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,571,154 kWh $ 249,980 $ 0.072 /kWh

- Demand Charge

 5,314 kW $ 9,193 $ 1.73 /kW

TOTAL ENERGY

 36,605 MMBtu $ 259,173 -
02 view
details		 REPLACE BROKEN WINDOWS AND/OR WINDOW SASH 2.7441 N $ 500,000 $ 145,366 3.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,501,642 kWh $ 105,116 $ 0.072 /kWh

Natural Gas

 7,537 MMBtu $ 40,250 $ 5.34 /MMBtu

TOTAL ENERGY

 22,929 MMBtu $ 145,366 -
03 view
details		 KEEP EQUIPMENT CLEAN 2.6125 I $ 0 $ 5,750 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,076 MMBtu $ 5,750 $ 5.34 /MMBtu

TOTAL ENERGY

 1,076 MMBtu $ 5,750 -
04 view
details		 REPLACE BROKEN WINDOWS AND/OR WINDOW SASH 2.7441 I $ 250 $ 1,597 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,822 kWh $ 1,597 $ 0.072 /kWh

TOTAL ENERGY

 234 MMBtu $ 1,597 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 2,410 $ 1,212 1.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,326 kWh $ 1,212 $ 0.072 /kWh

TOTAL ENERGY

 178 MMBtu $ 1,212 -
06 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 10,240 $ 15,198 0.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 202,675 kWh $ 15,198 $ 0.072 /kWh

TOTAL ENERGY

 2,077 MMBtu $ 15,198 -
07 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 9,660 $ 1,315 7.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,820 kWh $ 1,315 $ 0.072 /kWh

TOTAL ENERGY

 152 MMBtu $ 1,315 -
08 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 300 $ 186 1.61
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,662 kWh $ 186 $ 0.072 /kWh

TOTAL ENERGY

 27 MMBtu $ 186 -
09 view
details		 MAINTAIN AIR FILTERS BY CLEANING OR REPLACEMENT 2.6127 I $ 100 $ 2,104 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,847 kWh $ 2,019 $ 0.072 /kWh

- Demand Charge

 4,945 kW $ 85 $ 1.73 /kW

TOTAL ENERGY

 296 MMBtu $ 2,104 -
10 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 3,259 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 44,674 kWh $ 3,127 $ 0.072 /kWh

- Demand Charge

 76 kW $ 132 $ 1.73 /kW

TOTAL ENERGY

 458 MMBtu $ 3,259 -
11 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,300 $ 6,919 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 94,720 kWh $ 6,630 $ 0.072 /kWh

- Demand Charge

 167 kW $ 289 $ 1.73 /kW

TOTAL ENERGY

 971 MMBtu $ 6,919 -
12 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 3,016 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,094 kWh $ 3,016 $ 0.072 /kWh

TOTAL ENERGY

 442 MMBtu $ 3,016 -
13 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 0 $ 2,940 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,000 kWh $ 2,940 $ 0.072 /kWh

TOTAL ENERGY

 431 MMBtu $ 2,940 -
14 view
details		 KEEP DOORS AND WINDOWS SHUT WHEN NOT ON USE 2.7442 I $ 2,000 $ 3,194 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,644 kWh $ 3,194 $ 0.072 /kWh

TOTAL ENERGY

 468 MMBtu $ 3,194 -
15 view
details		 USE OPTIMUM THICKNESS INSULATION 2.2515 N $ 5,000 $ 11,828 0.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 168,984 kWh $ 11,828 $ 0.072 /kWh

TOTAL ENERGY

 1,732 MMBtu $ 11,828 -
16 view
details		 REPAIR FURNACES AND OVEN DOORS SO THAT THEY SEAL EFFICIENTLY 2.1135 I $ 50 $ 52 0.96
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 754 kWh $ 52 $ 0.072 /kWh

TOTAL ENERGY

 8 MMBtu $ 52 -
17 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 0 $ 652 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,980 kWh $ 558 $ 0.072 /kWh

- Demand Charge

 54 kW $ 94 $ 1.73 /kW

TOTAL ENERGY

 82 MMBtu $ 652 -
18 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 0 $ 12,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 1,200 kW $ 12,000 $ 1.73 /kW

TOTAL ENERGY

 0 MMBtu $ 12,000 -
19 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 18,000 $ 19,660 0.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 401,686 kWh $ 19,660 $ 0.072 /kWh

TOTAL ENERGY

 4,117 MMBtu $ 19,660 -
20 view
details		 REPLACE EXISTING HVAC UNIT WITH HIGH EFFICIENCY MODEL 2.7232 N $ 48,840 $ 14,800 3.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 211,428 kWh $ 14,800 $ 0.072 /kWh

TOTAL ENERGY

 2,167 MMBtu $ 14,800 -
21 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 300 $ 248 1.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 73 MMBtu $ 248 $ 5.34 /MMBtu

TOTAL ENERGY

 73 MMBtu $ 248 -