Industrial Assessment Centers

Assessment #NC0292


Assessment Year 2004
SIC 2677
SIC Description Envelopes
NAICS 322232
NAICS Description Envelope Manufacturing
Principal Product Mailing envelopes
Sales $ 18,000,000
# of Employees 128
Plant Area (Sq.Ft.) 133,436
Annual Production 1,100,000,000 Pieces
Production Hrs. Annual 6,000
Location (State) VA
Yearly Energy Cost $ 233,597

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

5,586,000 kWh $ 89,568 $ 0.016 /kWh

- Demand Charge

10,772 kW $ 89,840 $ 8.34 /kW

- Electricity Fees

- $ 14,400 -

Natural Gas

3,921 MMBtu $ 39,789 $ 10.15 /MMBtu

TOTAL ENERGY

61,178 MMBtu $ 233,597 $ 3.82 /MMBtu

Water Disposal

5,048 Gal $ 18,893 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

274,126 kWh
0 kWh
$ 4,279
$ 0
4.78 %
0.00 %
$ 0.016 /kWh

- Demand Charge

469 kW
0 kW
$ 3,919
$ 0
4.36 %
0.00 %
$ 8.34 /kW

- Electricity Fees

- $ 0
$ 0
0.00 %
0.00 %
-

Natural Gas

1,203 MMBtu
0 MMBtu
$ 12,210
$ 0
30.69 %
0.00 %
$ 10.15 /MMBtu

TOTAL ENERGY

4,013 MMBtu
0 MMBtu
$ 20,408
$ 0
8.74 %
0.00 %
$ 3.82 /MMBtu

Water Disposal

2,370,000 Gal
0 Gal
$ 17,751
$ 0
93.96 %
0.00 %
$ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details
MODIFY CURRENT INCENTIVE PROGRAM 4.4210 K $ 10,376 $ 53,200 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

- $ -36,800 -

Primary Raw Material

- $ -90,000 -

Increase in Production

- $ 180,000 -

TOTAL PRODUCTON

- $ 53,200 -
02 view
details
REPLACE CITY WATER WITH RECYCLED WATER VIA COOLING TOWER 3.4114 K $ 16,000 $ 17,751 0.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

2,370,000 Gal $ 17,751 $ 0 /Gal

TOTAL WASTE

- $ 17,751 -
03 view
details
UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 K $ 6,692 $ 5,368 1.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

166,243 kWh $ 2,595 $ 0.016 /kWh

- Demand Charge

332 kW $ 2,773 $ 8.34 /kW

TOTAL ENERGY

1,704 MMBtu $ 5,368 -
04 view
details
RECOVER HEAT FROM AIR COMPRESSOR 2.2434 K $ 2,738 $ 8,211 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

809 MMBtu $ 8,211 $ 10.15 /MMBtu

TOTAL ENERGY

809 MMBtu $ 8,211 -
05 view
details
RECYCLE AIR FOR HEATING, VENTILATION AND AIR CONDITIONING 2.7313 K $ 6,553 $ 4,313 1.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

20,129 kWh $ 314 $ 0.016 /kWh

Natural Gas

394 MMBtu $ 3,999 $ 10.15 /MMBtu

TOTAL ENERGY

600 MMBtu $ 4,313 -
06 view
details
RECOVER HEAT FROM OVEN EXHAUST / KILNS 2.2432 K $ 720 $ 1,084 0.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

33,600 kWh $ 524 $ 0.016 /kWh

- Demand Charge

67 kW $ 560 $ 8.34 /kW

TOTAL ENERGY

344 MMBtu $ 1,084 -
07 view
details
ADD AREA LIGHTING SWITCHES 2.7131 K $ 750 $ 297 2.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

19,002 kWh $ 297 $ 0.016 /kWh

TOTAL ENERGY

195 MMBtu $ 297 -
08 view
details
ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 K $ 100 $ 115 0.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

35,152 kWh $ 549 $ 0.016 /kWh

- Demand Charge

70 kW $ 586 $ 8.34 /kW

TOTAL ENERGY

360 MMBtu $ 1,135 -

Personnel Changes

- $ -720 -

Ancillary Material Cost

- $ -300 -

TOTAL PRODUCTON

- $ -1,020 -
09 view
details
LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER 3.5315 K $ 50 $ 45 1.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

10,400 lbs $ 142 $ 0 /lbs

TOTAL WASTE

- $ 142 -

Personnel Changes

- $ -144 -

By-product Production

- $ 47 -

TOTAL PRODUCTON

- $ -97 -