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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #NC0308


Assessment Year 2005
SIC 2657
SIC Description Folding Paperboard Boxes
NAICS 322212
NAICS Description Folding Paperboard Box Manufacturing
Principal Product Cartons for the food industry
Sales $ 38,000,000
# of Employees 124
Plant Area (Sq.Ft.) 156,000
Annual Production 999,999,999 Pieces
Production Hrs. Annual 8,400
Location (State) NC
Yearly Energy Cost $ 395,613

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 8,128,000 kWh $ 226,006 $ 0.028 /kWh

- Demand Charge

 14,799 kW $ 141,768 $ 9.58 /kW

- Electricity Fees

 - $ 12,059 -

Natural Gas

 1,566 MMBtu $ 15,780 $ 10.08 /MMBtu

TOTAL ENERGY

 84,878 MMBtu $ 395,613 $ 4.66 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 783,401 kWh
783,401 kWh		 $ 21,786
$ 21,786		 9.64 %
9.64 %		 $ 0.028 /kWh

- Demand Charge

 428 kW
428 kW		 $ 4,038
$ 4,038		 2.85 %
2.85 %		 $ 9.58 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 597 MMBtu
597 MMBtu		 $ 6,017
$ 6,017		 38.13 %
38.13 %		 $ 10.08 /MMBtu

TOTAL ENERGY

 8,627 MMBtu
8,627 MMBtu		 $ 31,841
$ 31,841		 8.05 %
8.05 %		 $ 4.66 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 I $ 20,313 $ 9,359 2.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 226,800 kWh $ 6,307 $ 0.028 /kWh

- Demand Charge

 324 kW $ 3,052 $ 9.58 /kW

TOTAL ENERGY

 2,325 MMBtu $ 9,359 -
02 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 2,450 $ 6,017 0.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 597 MMBtu $ 6,017 $ 10.08 /MMBtu

TOTAL ENERGY

 597 MMBtu $ 6,017 -
03 view
details		 CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE 4.2110 N $ 1,000 $ 15,600 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 15,600 -

TOTAL PRODUCTON

 - $ 15,600 -
04 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 I $ 6,500 $ 13,767 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 495,024 kWh $ 13,767 $ 0.028 /kWh

TOTAL ENERGY

 5,074 MMBtu $ 13,767 -
05 view
details		 ADOPT IN-HOUSE MATERIAL GENERATION 4.2120 N $ 4,000 $ 3,600 1.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 3,600 -

TOTAL PRODUCTON

 - $ 3,600 -
06 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 2,000 $ 1,493 1.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,943 kWh $ 972 $ 0.028 /kWh

- Demand Charge

 55 kW $ 521 $ 9.58 /kW

TOTAL ENERGY

 358 MMBtu $ 1,493 -
07 view
details		 INSTALL TIMERS ON LIGHT SWITCHES IN LITTLE USED AREAS 2.7132 I $ 750 $ 867 0.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,630 kWh $ 629 $ 0.028 /kWh

- Demand Charge

 25 kW $ 238 $ 9.58 /kW

TOTAL ENERGY

 232 MMBtu $ 867 -
08 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 I $ 160 $ 338 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,004 kWh $ 111 $ 0.028 /kWh

- Demand Charge

 24 kW $ 227 $ 9.58 /kW

TOTAL ENERGY

 41 MMBtu $ 338 -