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U.S. Department of Energy Energy Efficiency and Renewable Energy
IAC Field Managers

Industrial Assessment Centers

Assessment #SD0275


Assessment Year 2001
SIC 3089
SIC Description Plastics Products, Nec
NAICS
NAICS Description
Principal Product Awards and trophies
Sales $ 46,000,000
# of Employees 484
Plant Area (Sq.Ft.) 250,000
Annual Production 53,000,000 Pieces
Production Hrs. Annual 6,120
Location (State) CA
Yearly Energy Cost $ 615,834

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,519,857 kWh $ 375,995 $ 0.050 /kWh

- Demand Charge

 17,252 kW $ 168,640 $ 9.78 /kW

- Electricity Fees

 - $ 5,091 -

Natural Gas

 11,268 MMBtu $ 66,108 $ 5.87 /MMBtu

TOTAL ENERGY

 88,347 MMBtu $ 615,834 $ 6.97 /MMBtu

Water Disposal

 7,132,928 Gal $ 15,004 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 711,029 kWh
425,259 kWh		 $ 35,550
$ 21,262		 9.45 %
5.65 %		 $ 0.050 /kWh

- Demand Charge

 3,202 kW
2,742 kW		 $ 32,702
$ 28,206		 19.39 %
16.73 %		 $ 9.78 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 5.87 /MMBtu

TOTAL ENERGY

 7,288 MMBtu
4,359 MMBtu		 $ 68,252
$ 49,468		 11.08 %
8.03 %		 $ 6.97 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 I $ 1,000 $ 4,842 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 70,039 kWh $ 3,502 $ 0.050 /kWh

- Demand Charge

 137 kW $ 1,340 $ 9.78 /kW

TOTAL ENERGY

 718 MMBtu $ 4,842 -
02 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 700 $ 2,972 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,969 kWh $ 2,148 $ 0.050 /kWh

- Demand Charge

 84 kW $ 824 $ 9.78 /kW

TOTAL ENERGY

 440 MMBtu $ 2,972 -
03 view
details		 ELIMINATE PERMANENTLY THE USE OF COMPRESSED AIR 2.4233 N $ 7,000 $ 4,366 1.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 63,112 kWh $ 3,156 $ 0.050 /kWh

- Demand Charge

 124 kW $ 1,210 $ 9.78 /kW

TOTAL ENERGY

 647 MMBtu $ 4,366 -
04 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET 2.4142 P $ 18,000 $ 11,446 1.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 179,689 kWh $ 8,984 $ 0.050 /kWh

- Demand Charge

 252 kW $ 2,462 $ 9.78 /kW

TOTAL ENERGY

 1,842 MMBtu $ 11,446 -
05 view
details		 RECHARGE BATTERIES ON DURING OFF-PEAK DEMAND PERIODS 2.3132 I $ 0 $ 4,210 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 288 kW $ 4,210 $ 9.78 /kW

TOTAL ENERGY

 0 MMBtu $ 4,210 -
06 view
details		 INSTALL SKYLIGHTS 2.7145 I $ 12,500 $ 34,893 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 275,369 kWh $ 13,768 $ 0.050 /kWh

- Demand Charge

 2,160 kW $ 21,125 $ 9.78 /kW

TOTAL ENERGY

 2,823 MMBtu $ 34,893 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,080 $ 5,523 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 79,851 kWh $ 3,992 $ 0.050 /kWh

- Demand Charge

 157 kW $ 1,531 $ 9.78 /kW

TOTAL ENERGY

 818 MMBtu $ 5,523 -
08 view
details		 INSTALL EQUIPMENT (eg COMPACTOR) TO REDUCE DISPOSAL COSTS 3.6193 N $ 5,400 $ 2,888 1.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ -100 -

One-time Revenue or Avoided Cost

 - $ 2,988 -

TOTAL PRODUCTON

 - $ 2,888 -
09 view
details		 USE A RECYCLED RAW MATERIAL 3.1174 N $ 0 $ 45,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 900,000 lbs $ 45,000 $ 0 /lbs

TOTAL WASTE

 - $ 45,000 -
10 view
details		 SALVAGE AND RE-USE PROCESS WASTE 3.5312 N $ 20,000 $ 312,500 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 312,500 -

TOTAL PRODUCTON

 - $ 312,500 -
11 view
details		 INSTALL EQUIPMENT TO MOVE PRODUCT 4.4450 N $ 1,500 $ 73,440 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 73,440 -

TOTAL PRODUCTON

 - $ 73,440 -
12 view
details		 INSTALL AUTOMATIC PACKING EQUIPMENT 4.4410 N $ 35,000 $ 144,380 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 146,880 -

Administrative Changes

 - $ -2,500 -

TOTAL PRODUCTON

 - $ 144,380 -
13 view
details		 AUTOMATE FINISHING PROCESS 4.4460 N $ 80,000 $ 41,960 1.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 48,960 -

Administrative Changes

 - $ -7,000 -

TOTAL PRODUCTON

 - $ 41,960 -
14 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.6520 N $ 0 $ 6,420 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 6,120 -

One-time Revenue or Avoided Cost

 - $ 300 -

TOTAL PRODUCTON

 - $ 6,420 -
15 view
details		 INSTALL SYSTEM TO COLLECT SCRAP 4.4440 N $ 12,000 $ 73,440 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 73,440 -

TOTAL PRODUCTON

 - $ 73,440 -
16 view
details		 INSTALL AUTOMATIC PACKING EQUIPMENT 4.4410 N $ 60,000 $ 68,440 0.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 73,440 -

Administrative Changes

 - $ -5,000 -

TOTAL PRODUCTON

 - $ 68,440 -
17 view
details		 SCHEDULE DELIVERIES ACCORDING TO DEMAND 4.3110 N $ 210,000 $ 390,000 0.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

One-time Revenue or Avoided Cost

 - $ 390,000 -

TOTAL PRODUCTON

 - $ 390,000 -