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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #OK0806


Assessment Year 2011
SIC 3085
SIC Description Plastics Bottles
NAICS 326160
NAICS Description Plastics Bottle Manufacturing
Principal Product Plastic Gas Cans
Sales $ 78,000,000
# of Employees 280
Plant Area (Sq.Ft.) 600,000
Annual Production 15,000,000 Pieces
Production Hrs. Annual 8,760
Location (State) OK
Yearly Energy Cost $ 1,018,102

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 21,091,222 kWh $ 615,863 $ 0.029 /kWh

- Demand Charge

 40,308 kW $ 401,468 $ 9.96 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 44 MMBtu $ 771 $ 17.53 /MMBtu

TOTAL ENERGY

 216,231 MMBtu $ 1,018,102 $ 4.71 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,897,031 kWh
514,509 kWh		 $ 154,413
$ 27,425		 25.07 %
4.45 %		 $ 0.029 /kWh

- Demand Charge

 0 kW
0 kW		 $ 0
$ 0		 0.00 %
0.00 %		 $ 9.96 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 17.53 /MMBtu

TOTAL ENERGY

 29,695 MMBtu
5,274 MMBtu		 $ 154,413
$ 27,425		 15.17 %
2.69 %		 $ 4.71 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 57,500 $ 109,231 0.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,049,363 kWh $ 109,231 $ 0.029 /kWh

TOTAL ENERGY

 21,006 MMBtu $ 109,231 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 37,707 $ 10,484 3.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 196,704 kWh $ 10,484 $ 0.029 /kWh

TOTAL ENERGY

 2,016 MMBtu $ 10,484 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 38,005 $ 7,177 5.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 134,659 kWh $ 7,177 $ 0.029 /kWh

TOTAL ENERGY

 1,380 MMBtu $ 7,177 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 7,724 $ 1,415 5.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,539 kWh $ 1,415 $ 0.029 /kWh

TOTAL ENERGY

 272 MMBtu $ 1,415 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,600 $ 5,172 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 107,814 kWh $ 5,747 $ 0.029 /kWh

TOTAL ENERGY

 1,105 MMBtu $ 5,747 -

Personnel Changes

 - $ -575 -

TOTAL PRODUCTON

 - $ -575 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 414 $ 2,602 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 48,793 kWh $ 2,602 $ 0.029 /kWh

TOTAL ENERGY

 500 MMBtu $ 2,602 -
07 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 N $ 870 $ 8,222 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 154,264 kWh $ 8,222 $ 0.029 /kWh

TOTAL ENERGY

 1,581 MMBtu $ 8,222 -
08 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 2,964 $ 6,859 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 128,687 kWh $ 6,859 $ 0.029 /kWh

TOTAL ENERGY

 1,319 MMBtu $ 6,859 -
09 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 7,130 $ 2,676 2.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 50,208 kWh $ 2,676 $ 0.029 /kWh

TOTAL ENERGY

 515 MMBtu $ 2,676 -