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

Industrial Assessment Centers

Assessment #NC0423


Assessment Year 2011
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product PVC mouldings
Sales $ 20,000,000
# of Employees 450
Plant Area (Sq.Ft.) 500,000
Annual Production 90,500,000 Pounds
Production Hrs. Annual 8,400
Location (State) VA
Yearly Energy Cost $ 2,786,543

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 34,404,450 kWh $ 1,529,622 $ 0.044 /kWh

- Demand Charge

 62,223 kW $ 620,986 $ 9.98 /kW

- Electricity Fees

 - $ 252,845 -

Natural Gas

 70,676 MMBtu $ 383,090 $ 5.42 /MMBtu

TOTAL ENERGY

 423,325 MMBtu $ 2,786,543 $ 6.58 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,818,603 kWh
3,239,428 kWh		 $ 169,774
$ 144,024		 11.10 %
9.42 %		 $ 0.044 /kWh

- Demand Charge

 4,173 kW
3,484 kW		 $ 41,653
$ 34,779		 6.71 %
5.60 %		 $ 9.98 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 20,588 MMBtu
0 MMBtu		 $ 111,589
$ 0		 29.13 %
0.00 %		 $ 5.42 /MMBtu

TOTAL ENERGY

 59,729 MMBtu
33,204 MMBtu		 $ 323,016
$ 178,803		 11.59 %
6.42 %		 $ 6.58 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSTALL REFRIGERATION SYSTEM TO COOL PRODUCT 4.113 I $ 650,000 $ 1,468,749 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,380,664 kWh $ 105,844 $ 0.044 /kWh

- Demand Charge

 2,256 kW $ 22,515 $ 9.98 /kW

TOTAL ENERGY

 24,402 MMBtu $ 128,359 -

Water Consumption

 - $ -29,610 -

Primary Product

 - $ 1,370,000 -

TOTAL PRODUCTON

 - $ 1,340,390 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 100 $ 6,736 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 128,800 kWh $ 5,726 $ 0.044 /kWh

- Demand Charge

 185 kW $ 1,850 $ 9.98 /kW

TOTAL ENERGY

 1,320 MMBtu $ 7,576 -

Personnel Changes

 - $ -600 -

Ancillary Material Cost

 - $ -240 -

TOTAL PRODUCTON

 - $ -840 -
03 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 60,000 $ 26,211 2.29
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 482,160 kWh $ 21,437 $ 0.044 /kWh

- Demand Charge

 689 kW $ 6,874 $ 9.98 /kW

TOTAL ENERGY

 4,942 MMBtu $ 28,311 -

Water Consumption

 - $ -2,100 -

TOTAL PRODUCTON

 - $ -2,100 -
04 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 42,000 $ 24,869 1.69
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,588 MMBtu $ 24,869 $ 5.42 /MMBtu

TOTAL ENERGY

 4,588 MMBtu $ 24,869 -
05 view
details		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 N $ 87,892 $ 86,720 1.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 16,000 MMBtu $ 86,720 $ 5.42 /MMBtu

TOTAL ENERGY

 16,000 MMBtu $ 86,720 -
06 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 115,608 $ 34,209 3.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 675,058 kWh $ 30,013 $ 0.044 /kWh

- Demand Charge

 964 kW $ 9,625 $ 9.98 /kW

TOTAL ENERGY

 6,919 MMBtu $ 39,638 -

Ancillary Material Cost

 - $ -5,429 -

TOTAL PRODUCTON

 - $ -5,429 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,585 $ 3,230 1.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,906 kWh $ 2,441 $ 0.044 /kWh

- Demand Charge

 79 kW $ 789 $ 9.98 /kW

TOTAL ENERGY

 563 MMBtu $ 3,230 -
08 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 12,378 $ 4,313 2.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 97,015 kWh $ 4,313 $ 0.044 /kWh

TOTAL ENERGY

 994 MMBtu $ 4,313 -