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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #OK0691


Assessment Year 2004
SIC 3585
SIC Description Refrigeration And Heating Equipment
NAICS 333415
NAICS Description Air-Conditioning and Warm Air Heating Equipment and Commercial and Industrial Refrigeration Equipmen
Principal Product Walk-In Coolers and Freezers
Sales $ 12,000,000
# of Employees 100
Plant Area (Sq.Ft.) 47,000
Annual Production 600 Pieces
Production Hrs. Annual 2,600
Location (State) KS
Yearly Energy Cost $ 60,113

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 604,097 kWh $ 29,299 $ 0.049 /kWh

- Demand Charge

 1,957 kW $ 10,329 $ 5.28 /kW

- Electricity Fees

 - $ 5,085 -

Natural Gas

 1,994 MMBtu $ 15,400 $ 7.72 /MMBtu

TOTAL ENERGY

 8,186 MMBtu $ 60,113 $ 7.34 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 73,059 kWh
67,817 kWh		 $ 3,633
$ 3,379		 12.40 %
11.53 %		 $ 0.049 /kWh

- Demand Charge

 0 kW
0 kW		 $ 0
$ 0		 0.00 %
0.00 %		 $ 5.28 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 846 MMBtu
846 MMBtu		 $ 6,531
$ 6,531		 42.41 %
42.41 %		 $ 7.72 /MMBtu

TOTAL ENERGY

 1,595 MMBtu
1,541 MMBtu		 $ 10,164
$ 9,910		 16.91 %
16.49 %		 $ 7.34 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSTALL EQUIPMENT TO MOVE PRODUCT 4.4450 N $ 5,782 $ 90,154 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 90,154 -

TOTAL PRODUCTON

 - $ 90,154 -
02 view
details		 EMPLOY MODULAR JIGS TO REDUCE PROCESS SET-UP TIME 4.6230 I $ 2,825 $ 270,439 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 270,439 -

TOTAL PRODUCTON

 - $ 270,439 -
03 view
details		 INSTALL SET-BACK TIMERS 2.6232 I $ 3,832 $ 6,531 0.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 846 MMBtu $ 6,531 $ 7.72 /MMBtu

TOTAL ENERGY

 846 MMBtu $ 6,531 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 559 $ 2,036 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 49,896 kWh $ 2,228 $ 0.049 /kWh

TOTAL ENERGY

 511 MMBtu $ 2,228 -

Personnel Changes

 - $ -192 -

TOTAL PRODUCTON

 - $ -192 -
05 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 265 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,460 kWh $ 265 $ 0.049 /kWh

TOTAL ENERGY

 56 MMBtu $ 265 -
06 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 760 $ 254 2.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,242 kWh $ 254 $ 0.049 /kWh

TOTAL ENERGY

 54 MMBtu $ 254 -
07 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 I $ 139 $ 886 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,461 kWh $ 886 $ 0.049 /kWh

TOTAL ENERGY

 128 MMBtu $ 886 -