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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #OK0682


Assessment Year 2004
SIC 2392
SIC Description Housefurnishings, Nec
NAICS 314129
NAICS Description Other Household Textile Product Mills
Principal Product Bedding Pillows, Comforters, Texile
Sales $ 40,000,000
# of Employees 100
Plant Area (Sq.Ft.) 100,000
Annual Production 7,800,000 Pieces
Production Hrs. Annual 6,240
Location (State) OK
Yearly Energy Cost $ 99,454

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,584,300 kWh $ 74,273 $ 0.047 /kWh

- Electricity Fees

 - $ 5,593 -

Natural Gas

 2,492 MMBtu $ 19,588 $ 7.86 /MMBtu

TOTAL ENERGY

 18,731 MMBtu $ 99,454 $ 5.31 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 280,398 kWh
128,085 kWh		 $ 8,974
$ 4,099		 12.08 %
5.52 %		 $ 0.047 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 767 MMBtu
200 MMBtu		 $ 6,027
$ 1,572		 30.77 %
8.03 %		 $ 7.86 /MMBtu

TOTAL ENERGY

 3,641 MMBtu
1,513 MMBtu		 $ 16,564
$ 5,884		 16.65 %
5.92 %		 $ 5.31 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSTALL SET-BACK TIMERS 2.6232 I $ 163 $ 1,572 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 200 MMBtu $ 1,572 $ 7.86 /MMBtu

TOTAL ENERGY

 200 MMBtu $ 1,572 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 6,187 $ 906 6.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,680 kWh $ 566 $ 0.047 /kWh

- Demand Charge

 82 kW $ 354 $ 0.00 /kW

TOTAL ENERGY

 181 MMBtu $ 920 -

Ancillary Material Cost

 - $ -14 -

TOTAL PRODUCTON

 - $ -14 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 200 $ 96 2.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,352 kWh $ 43 $ 0.047 /kWh

- Demand Charge

 6 kW $ 27 $ 0.00 /kW

TOTAL ENERGY

 14 MMBtu $ 70 -

Ancillary Material Cost

 - $ 26 -

TOTAL PRODUCTON

 - $ 26 -
04 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 682 $ 738 0.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,072 kWh $ 738 $ 0.047 /kWh

TOTAL ENERGY

 236 MMBtu $ 738 -
05 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 3,000 $ 419 7.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,256 kWh $ 168 $ 0.047 /kWh

- Demand Charge

 7 kW $ 31 $ 0.00 /kW

TOTAL ENERGY

 54 MMBtu $ 199 -

Ancillary Material Cost

 - $ 220 -

TOTAL PRODUCTON

 - $ 220 -
06 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 92 $ 132 0.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,113 kWh $ 132 $ 0.047 /kWh

TOTAL ENERGY

 42 MMBtu $ 132 -
07 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 15,000 $ 3,374 4.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 83,616 kWh $ 2,676 $ 0.047 /kWh

- Demand Charge

 161 kW $ 698 $ 0.00 /kW

TOTAL ENERGY

 857 MMBtu $ 3,374 -
08 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 2,134 $ 4,455 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 567 MMBtu $ 4,455 $ 7.86 /MMBtu

TOTAL ENERGY

 567 MMBtu $ 4,455 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 438 $ 892 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,173 kWh $ 710 $ 0.047 /kWh

- Demand Charge

 41 kW $ 182 $ 0.00 /kW

TOTAL ENERGY

 227 MMBtu $ 892 -
10 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 I $ 1,200 $ 2,483 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 77,584 kWh $ 2,483 $ 0.047 /kWh

TOTAL ENERGY

 795 MMBtu $ 2,483 -
11 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 130 $ 1,729 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,552 kWh $ 1,458 $ 0.047 /kWh

- Demand Charge

 62 kW $ 271 $ 0.00 /kW

TOTAL ENERGY

 467 MMBtu $ 1,729 -
12 view
details		 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK 4.1110 I $ 10,000 $ 15,392 0.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 15,392 -

TOTAL PRODUCTON

 - $ 15,392 -
13 view
details		 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE 4.6110 I $ 0 $ 1,600 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ -2,000 -

Ancillary Material Cost

 - $ 3,600 -

TOTAL PRODUCTON

 - $ 1,600 -