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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #ND0175


Assessment Year 1993
SIC 3822
SIC Description Environmental Controls
NAICS
NAICS Description
Principal Product App. Timers and Auto Switches
Sales $ 80,000,000
# of Employees 494
Plant Area (Sq.Ft.) 0
Annual Production 17,000,000 Pieces
Production Hrs. Annual 7,488
Location (State) IN
Yearly Energy Cost $ 490,983

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,368,699 kWh $ 425,273 $ 0.045 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 18,635 MMBtu $ 65,710 $ 3.53 /MMBtu

TOTAL ENERGY

 114,664 MMBtu $ 490,983 $ 4.28 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 832,649 kWh
0 kWh		 $ 83,571
$ 0		 19.65 %
0.00 %		 $ 0.045 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 346 MMBtu
0 MMBtu		 $ 1,437
$ 0		 2.19 %
0.00 %		 $ 3.53 /MMBtu

TOTAL ENERGY

 8,879 MMBtu
0 MMBtu		 $ 85,008
$ 0		 17.31 %
0.00 %		 $ 4.28 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE EXISTING HVAC UNIT WITH HIGH EFFICIENCY MODEL 2.7232 K $ 259,500 $ 62,950 4.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 522,274 kWh $ 62,950 $ 0.045 /kWh

TOTAL ENERGY

 5,353 MMBtu $ 62,950 -
02 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 K $ 14,600 $ 6,581 2.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 0 kWh $ 6,581 $ 0.045 /kWh

TOTAL ENERGY

 0 MMBtu $ 6,581 -
03 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 K $ 22,950 $ 5,783 3.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 127,491 kWh $ 5,783 $ 0.045 /kWh

TOTAL ENERGY

 1,307 MMBtu $ 5,783 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 K $ 910 $ 2,617 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,910 kWh $ 2,617 $ 0.045 /kWh

TOTAL ENERGY

 604 MMBtu $ 2,617 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 K $ 600 $ 1,587 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,877 kWh $ 1,587 $ 0.045 /kWh

TOTAL ENERGY

 357 MMBtu $ 1,587 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 K $ 500 $ 1,507 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,118 kWh $ 1,507 $ 0.045 /kWh

TOTAL ENERGY

 339 MMBtu $ 1,507 -
07 view
details		 INSTALL WEATHER STRIPPING ON WINDOWS AND DOORS 2.7445 K $ 1,140 $ 1,437 0.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 346 MMBtu $ 1,437 $ 3.53 /MMBtu

TOTAL ENERGY

 346 MMBtu $ 1,437 -
08 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 K $ 0 $ 1,052 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,154 kWh $ 1,052 $ 0.045 /kWh

TOTAL ENERGY

 237 MMBtu $ 1,052 -
09 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 K $ 300 $ 680 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,947 kWh $ 680 $ 0.045 /kWh

TOTAL ENERGY

 153 MMBtu $ 680 -
10 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 K $ 0 $ 677 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,947 kWh $ 677 $ 0.045 /kWh

TOTAL ENERGY

 153 MMBtu $ 677 -
11 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 K $ 150 $ 137 1.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,931 kWh $ 137 $ 0.045 /kWh

TOTAL ENERGY

 30 MMBtu $ 137 -