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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #NC0314


Assessment Year 2005
SIC 3251
SIC Description Brick And Structural Clay Tile
NAICS 327121
NAICS Description Brick and Structural Clay Tile Manufacturing
Principal Product Bricks
Sales $ 10,000,000
# of Employees 60
Plant Area (Sq.Ft.) 120,000
Annual Production 55,000,000 Pieces
Production Hrs. Annual 8,400
Location (State) NC
Yearly Energy Cost $ 1,409,419

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,942,700 kWh $ 190,445 $ 0.048 /kWh

- Demand Charge

 17,364 kW $ 59,906 $ 3.45 /kW

- Electricity Fees

 - $ 5,696 -

Natural Gas

 180,160 MMBtu $ 1,153,372 $ 6.40 /MMBtu

TOTAL ENERGY

 220,573 MMBtu $ 1,409,419 $ 6.39 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 255,221 kWh
246,236 kWh		 $ 11,087
$ 10,697		 5.82 %
5.62 %		 $ 0.048 /kWh

- Demand Charge

 333 kW
320 kW		 $ 1,153
$ 1,108		 1.92 %
1.85 %		 $ 3.45 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,335 MMBtu
1,335 MMBtu		 $ 8,544
$ 8,544		 0.74 %
0.74 %		 $ 6.40 /MMBtu

TOTAL ENERGY

 3,951 MMBtu
3,859 MMBtu		 $ 20,784
$ 20,349		 1.47 %
1.44 %		 $ 6.39 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 1,824 $ 8,544 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,335 MMBtu $ 8,544 $ 6.40 /MMBtu

TOTAL ENERGY

 1,335 MMBtu $ 8,544 -
02 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 1,393 $ 848 1.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 15,285 kWh $ 664 $ 0.048 /kWh

- Demand Charge

 53 kW $ 184 $ 3.45 /kW

TOTAL ENERGY

 157 MMBtu $ 848 -
03 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 379 $ 1,259 0.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,620 kWh $ 852 $ 0.048 /kWh

- Demand Charge

 118 kW $ 407 $ 3.45 /kW

TOTAL ENERGY

 201 MMBtu $ 1,259 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 100 $ 1,022 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,570 kWh $ 1,458 $ 0.048 /kWh

- Demand Charge

 134 kW $ 464 $ 3.45 /kW

TOTAL ENERGY

 344 MMBtu $ 1,922 -

Personnel Changes

 - $ -600 -

Administrative Changes

 - $ -300 -

TOTAL PRODUCTON

 - $ -900 -
05 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 2,552 $ 7,252 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 166,925 kWh $ 7,252 $ 0.048 /kWh

TOTAL ENERGY

 1,711 MMBtu $ 7,252 -
06 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 660 $ 1,356 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,836 kWh $ 471 $ 0.048 /kWh

- Demand Charge

 15 kW $ 53 $ 3.45 /kW

TOTAL ENERGY

 111 MMBtu $ 524 -

Personnel Changes

 - $ 847 -

Administrative Changes

 - $ -15 -

TOTAL PRODUCTON

 - $ 832 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 367 $ 435 0.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,985 kWh $ 390 $ 0.048 /kWh

- Demand Charge

 13 kW $ 45 $ 3.45 /kW

TOTAL ENERGY

 92 MMBtu $ 435 -