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

Industrial Assessment Centers

Assessment #NC0455


Assessment Year 2012
SIC 3085
SIC Description Plastics Bottles
NAICS 326160
NAICS Description Plastics Bottle Manufacturing
Principal Product Plastic parts
Sales $ 12,000,000
# of Employees 51
Plant Area (Sq.Ft.) 51,200
Annual Production 2,600,000 Pounds
Production Hrs. Annual 8,700
Location (State) NC
Yearly Energy Cost $ 661,954

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,145,611 kWh $ 412,302 $ 0.058 /kWh

- Demand Charge

 13,034 kW $ 236,559 $ 18.15 /kW

- Electricity Fees

 - $ 7,416 -

Natural Gas

 626 MMBtu $ 5,677 $ 9.07 /MMBtu

TOTAL ENERGY

 73,869 MMBtu $ 661,954 $ 8.96 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 294,078 kWh
265,010 kWh		 $ 16,971
$ 15,294		 4.12 %
3.71 %		 $ 0.058 /kWh

- Demand Charge

 10,488 kW
10,445 kW		 $ 147,809
$ 146,902		 62.48 %
62.10 %		 $ 18.15 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 9.07 /MMBtu

TOTAL ENERGY

 2,278 MMBtu
1,980 MMBtu		 $ 145,585
$ 143,001		 21.99 %
21.60 %		 $ 8.96 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 2,419 $ 17,379 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 175,934 kWh $ 10,151 $ 0.058 /kWh

- Demand Charge

 344 kW $ 7,228 $ 18.15 /kW

TOTAL ENERGY

 1,803 MMBtu $ 17,379 -
02 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,600 $ 1,681 0.95
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,396 kWh $ 1,119 $ 0.058 /kWh

- Demand Charge

 27 kW $ 562 $ 18.15 /kW

TOTAL ENERGY

 199 MMBtu $ 1,681 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 383 $ 294 1.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,735 kWh $ 100 $ 0.058 /kWh

- Demand Charge

 9 kW $ 194 $ 18.15 /kW

TOTAL ENERGY

 18 MMBtu $ 294 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 100 $ 1,649 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,710 kWh $ 1,657 $ 0.058 /kWh

- Demand Charge

 40 kW $ 832 $ 18.15 /kW

TOTAL ENERGY

 294 MMBtu $ 2,489 -

Personnel Changes

 - $ -600 -

Ancillary Material Cost

 - $ -240 -

TOTAL PRODUCTON

 - $ -840 -
05 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 N $ 50 $ 452 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,220 kWh $ 301 $ 0.058 /kWh

- Demand Charge

 7 kW $ 151 $ 18.15 /kW

TOTAL ENERGY

 54 MMBtu $ 452 -
06 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 350 $ 157 2.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,717 kWh $ 157 $ 0.058 /kWh

TOTAL ENERGY

 28 MMBtu $ 157 -
07 view
details		 USE FOSSIL FUEL POWERED GENERATOR DURING PEAK DEMAND PERIODS 2.3192 I $ 50,000 $ 113,133 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 60,366 kWh $ 3,486 $ 0.058 /kWh

- Demand Charge

 10,061 kW $ 138,842 $ 18.15 /kW

Fuel Oil #2

 -736 MMBtu $ -19,195 $ 0.00 /MMBtu

TOTAL ENERGY

 -117 MMBtu $ 123,133 -

Administrative Changes

 - $ -10,000 -

TOTAL PRODUCTON

 - $ -10,000 -