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

Industrial Technologies Program

Assessment Year	2005
SIC	3089
SIC Description	Plastics Products, Nec
NAICS	326199
NAICS Description	All Other Plastics Product Manufacturing
Principal Product	Plastic Products
Sales	$ 95,000,000
# of Employees	450
Plant Area (Sq.Ft.)	800,000
Annual Production	15,000,000 Pieces
Production Hrs. Annual	8,760
Location (State)	KS
Yearly Energy Cost	$ 1,322,697

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	32,536,452 kWh	$ 932,608	$ 0.029 /kWh
- Demand Charge	55,746 kW	$ 334,367	$ 6.00 /kW
- Electricity Fees	-	$ 5,460	-
Natural Gas	6,817 MMBtu	$ 50,262	$ 7.37 /MMBtu
TOTAL ENERGY	340,316 MMBtu	$ 1,322,697	$ 3.89 /MMBtu

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	5,017,104 kWh 2,339,253 kWh	$ 158,262 $ 67,135	16.97 % 7.20 %	$ 0.029 /kWh
- Demand Charge	4,722 kW 1,122 kW	$ 28,291 $ 6,727	8.46 % 2.01 %	$ 6.00 /kW
- Electricity Fees	-	$ 0 $ 0	0.00 % 0.00 %	-
Natural Gas	0 MMBtu 0 MMBtu	$ 0 $ 0	0.00 % 0.00 %	$ 7.37 /MMBtu
TOTAL ENERGY	51,425 MMBtu 23,977 MMBtu	$ 186,553 $ 73,862	14.10 % 5.58 %	$ 3.89 /MMBtu

Recommendations

AR #		Description	ARC Code	Status	Cost	Savings	Payback (Years)
01	view details	USE COOLING TOWER WATER INSTEAD OF REFRIGERATION	2.2612	N	$ 34,300	$ 37,468	0.92
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 1,305,510 kWh $ 37,468 $ 0.029 /kWh TOTAL ENERGY 13,381 MMBtu $ 37,468 -
02	view details	USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM	2.4143	I	$ 25,020	$ 7,044	3.55
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 245,462 kWh $ 7,044 $ 0.029 /kWh TOTAL ENERGY 2,516 MMBtu $ 7,044 -
03	view details	USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM	2.4143	I	$ 39,180	$ 36,596	1.07
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 1,275,134 kWh $ 36,596 $ 0.029 /kWh TOTAL ENERGY 13,070 MMBtu $ 36,596 -
04	view details	USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET	2.4142	N	$ 1,739	$ 53,659	0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 1,372,341 kWh $ 53,659 $ 0.029 /kWh TOTAL ENERGY 14,066 MMBtu $ 53,659 -
05	view details	ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES	2.4236	I	$ 1,727	$ 21,204	0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 574,380 kWh $ 16,484 $ 0.029 /kWh - Demand Charge 787 kW $ 4,720 $ 6.00 /kW TOTAL ENERGY 5,887 MMBtu $ 21,204 -
06	view details	REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED	2.4231	I	$ 22,540	$ 9,018	2.50
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 244,277 kWh $ 7,011 $ 0.029 /kWh - Demand Charge 335 kW $ 2,007 $ 6.00 /kW TOTAL ENERGY 2,504 MMBtu $ 9,018 -
07	view details	CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE	2.8114	N	$ 0	$ 1,250	0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price Administrative Changes - $ 1,250 - TOTAL PRODUCTON - $ 1,250 -
08	view details	USE DEMAND CONTROLLER OR LOAD SHEDDER	2.3191	N	$ 1,025	$ 21,564	0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price - Demand Charge 3,600 kW $ 21,564 $ 6.00 /kW TOTAL ENERGY 0 MMBtu $ 21,564 -

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