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

Industrial Assessment Centers

Assessment #NC0428


Assessment Year 2011
SIC 3086
SIC Description Plastics Foam Products
NAICS 326150
NAICS Description Urethane and Other Foam Product (except Polystyrene) Manufacturing
Principal Product Foam insulation
Sales $ 29,700,000
# of Employees 81
Plant Area (Sq.Ft.) 500,000
Annual Production 30,000 Thousand Feet
Production Hrs. Annual 6,000
Location (State) NC
Yearly Energy Cost $ 680,758

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 5,472,454 kWh $ 343,404 $ 0.063 /kWh

- Demand Charge

 10,246 kW $ 299,212 $ 29.20 /kW

- Electricity Fees

 - $ 2,113 -

Natural Gas

 3,085 MMBtu $ 36,029 $ 11.68 /MMBtu

TOTAL ENERGY

 59,178 MMBtu $ 680,758 $ 11.50 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 953,198 kWh
1,078,198 kWh		 $ 58,684
$ 66,528		 17.09 %
19.37 %		 $ 0.063 /kWh

- Demand Charge

 8,830 kW
8,714 kW		 $ 237,004
$ 236,036		 79.21 %
78.89 %		 $ 29.20 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 168 MMBtu
168 MMBtu		 $ 1,962
$ 1,962		 5.45 %
5.45 %		 $ 11.68 /MMBtu

TOTAL ENERGY

 7,170 MMBtu
8,452 MMBtu		 $ 227,758
$ 234,634		 33.46 %
34.47 %		 $ 11.50 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE A FOSSIL FUEL ENGINE TO COGENERATE ELECTRICITY OR MOTIVE POWER; AND UTILIZE HEAT 2.3415 I $ 450,915 $ 145,527 3.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 299,377 kWh $ 18,786 $ 0.063 /kWh

- Demand Charge

 7,185 kW $ 194,671 $ 29.20 /kW

Natural Gas

 168 MMBtu $ 1,962 $ 11.68 /MMBtu

Fuel Oil #2

 -2,768 MMBtu $ -69,892 $ 0.00 /MMBtu

TOTAL ENERGY

 469 MMBtu $ 145,527 -
02 view
details		 IMPROVE SPACE COMFORT CONDITIONING 4.424 N $ 94,425 $ 60,444 1.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -125,000 kWh $ -7,844 $ 0.063 /kWh

- Demand Charge

 -250 kW $ -6,762 $ 29.20 /kW

TOTAL ENERGY

 -1,281 MMBtu $ -14,606 -

Ancillary Material Cost

 - $ -1,000 -

Primary Product

 - $ 76,050 -

TOTAL PRODUCTON

 - $ 75,050 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 287,294 $ 72,294 3.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 697,236 kWh $ 42,622 $ 0.063 /kWh

- Demand Charge

 1,358 kW $ 36,747 $ 29.20 /kW

TOTAL ENERGY

 7,147 MMBtu $ 79,369 -

Ancillary Material Cost

 - $ -7,075 -

TOTAL PRODUCTON

 - $ -7,075 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 13,050 $ 3,540 3.69
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,257 kWh $ 1,648 $ 0.063 /kWh

- Demand Charge

 70 kW $ 1,892 $ 29.20 /kW

TOTAL ENERGY

 269 MMBtu $ 3,540 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 750 $ 307 2.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,890 kWh $ 307 $ 0.063 /kWh

TOTAL ENERGY

 50 MMBtu $ 307 -
06 view
details		 MAKE ICE DURING OFF PEAK HOURS FOR COOLING 2.3113 N $ 47,000 $ 7,730 6.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 366 kW $ 7,730 $ 29.20 /kW

TOTAL ENERGY

 0 MMBtu $ 7,730 -
07 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 25 $ 4,910 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,038 kWh $ 2,638 $ 0.063 /kWh

- Demand Charge

 84 kW $ 2,272 $ 29.20 /kW

TOTAL ENERGY

 431 MMBtu $ 4,910 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 100 $ 681 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,400 kWh $ 527 $ 0.063 /kWh

- Demand Charge

 17 kW $ 454 $ 29.20 /kW

TOTAL ENERGY

 86 MMBtu $ 981 -

Personnel Changes

 - $ -180 -

Ancillary Material Cost

 - $ -120 -

TOTAL PRODUCTON

 - $ -300 -