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

Industrial Assessment Centers

Assessment #MZ0069


Assessment Year 2011
SIC 2759
SIC Description Commercial Printing, Nec
NAICS 323112
NAICS Description Commercial Flexographic Printing
Principal Product books
Sales $ 45,000,000
# of Employees 250
Plant Area (Sq.Ft.) 1,200,000
Annual Production 30,000,000 Pieces
Production Hrs. Annual 8,640
Location (State) MO
Yearly Energy Cost $ 709,274

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,409,837 kWh $ 586,903 $ 0.062 /kWh

- Demand Charge

 18,044 kW $ 36,919 $ 2.05 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 7,549 MMBtu $ 85,452 $ 11.32 /MMBtu

TOTAL ENERGY

 104,001 MMBtu $ 709,274 $ 6.82 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 158,683 kWh
114,481 kWh		 $ 9,909
$ 7,193		 1.69 %
1.23 %		 $ 0.062 /kWh

- Demand Charge

 6,656 kW
20 kW		 $ 13,880
$ 50		 37.60 %
0.14 %		 $ 2.05 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 3,215 MMBtu
3,215 MMBtu		 $ 36,400
$ 36,400		 42.60 %
42.60 %		 $ 11.32 /MMBtu

TOTAL ENERGY

 4,842 MMBtu
4,388 MMBtu		 $ 60,189
$ 43,643		 8.49 %
6.15 %		 $ 6.82 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE 2.4131 N $ 10,000 $ 1,000 10.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,667 kWh $ 1,000 $ 0.062 /kWh

TOTAL ENERGY

 171 MMBtu $ 1,000 -
02 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 4,830 $ 1,390 3.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,100 kWh $ 1,390 $ 0.062 /kWh

TOTAL ENERGY

 227 MMBtu $ 1,390 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 87 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,442 kWh $ 87 $ 0.062 /kWh

TOTAL ENERGY

 15 MMBtu $ 87 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 820 $ 5,586 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 88,723 kWh $ 5,586 $ 0.062 /kWh

TOTAL ENERGY

 909 MMBtu $ 5,586 -
05 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 1,000 $ 13,830 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 6,636 kW $ 13,830 $ 2.05 /kW

TOTAL ENERGY

 0 MMBtu $ 13,830 -
06 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 0 $ 326 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,435 kWh $ 326 $ 0.062 /kWh

TOTAL ENERGY

 56 MMBtu $ 326 -
07 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 0 $ 36,400 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,215 MMBtu $ 36,400 $ 11.32 /MMBtu

TOTAL ENERGY

 3,215 MMBtu $ 36,400 -
08 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 250 $ 630 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,512 kWh $ 630 $ 0.062 /kWh

TOTAL ENERGY

 108 MMBtu $ 630 -
09 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 2,600 $ 940 2.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,804 kWh $ 890 $ 0.062 /kWh

- Demand Charge

 20 kW $ 50 $ 2.05 /kW

TOTAL ENERGY

 141 MMBtu $ 940 -
10 view
details		 CONSIDER INTERMEDIATE OR ECONOMY SIZE AUTOS / TRUCKS 2.8221 N $ 85,000 $ 65,000 1.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Primary Product

 - $ 65,000 -

TOTAL PRODUCTON

 - $ 65,000 -
11 view
details		 ELIMINATE OLD STOCK AND MODIFY INVENTORY CONTROL 4.322 N $ 150,000 $ 120,000 1.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Primary Product

 - $ 120,000 -

TOTAL PRODUCTON

 - $ 120,000 -
12 view
details		 USE PLASTIC PALLETS INSTEAD OF WOOD 3.1163 N $ 5,000 $ 25,000 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Increase in Production

 - $ 25,000 -

TOTAL PRODUCTON

 - $ 25,000 -
13 view
details		 DEVELOP STANDARD PROCEDURES TO IMPROVE INTERNAL YIELDS 4.122 N $ 8,500 $ 35,000 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Primary Product

 - $ 35,000 -

TOTAL PRODUCTON

 - $ 35,000 -
14 view
details		 DEVELOP STANDARD PROCEDURES TO IMPROVE INTERNAL YIELDS 4.122 N $ 12,500 $ 115,000 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Primary Product

 - $ 115,000 -

TOTAL PRODUCTON

 - $ 115,000 -
15 view
details		 DEVELOP STANDARD PROCEDURES TO IMPROVE INTERNAL YIELDS 4.122 I $ 125,000 $ 115,000 1.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Primary Product

 - $ 115,000 -

TOTAL PRODUCTON

 - $ 115,000 -