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

Industrial Assessment Centers

Assessment #SU0302


Assessment Year 2011
SIC 3085
SIC Description Plastics Bottles
NAICS 326160
NAICS Description Plastics Bottle Manufacturing
Principal Product Injected Molded Plastics
Sales $ 83,500,000
# of Employees 168
Plant Area (Sq.Ft.) 106,000
Annual Production 242,000,000 Pieces
Production Hrs. Annual 8,424
Location (State) NY
Yearly Energy Cost $ 724,956

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,853,146 kWh $ 624,291 $ 0.063 /kWh

- Demand Charge

 20,123 kW $ 62,853 $ 3.12 /kW

- Electricity Fees

 - $ 10,168 -

Natural Gas

 3,563 MMBtu $ 27,644 $ 7.76 /MMBtu

TOTAL ENERGY

 104,559 MMBtu $ 724,956 $ 6.93 /MMBtu

Water Disposal

 748,053 Gal $ 2,469 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 449,223 kWh
208,611 kWh		 $ 28,480
$ 13,226		 4.56 %
2.12 %		 $ 0.063 /kWh

- Demand Charge

 -77 kW
70 kW		 $ -242
$ 217		 -0.39 %
0.35 %		 $ 3.12 /kW

- Electricity Fees

 - $ 3,646
$ 0		 35.86 %
0.00 %		 -

Natural Gas

 1,401 MMBtu
946 MMBtu		 $ 10,867
$ 7,336		 39.31 %
26.54 %		 $ 7.76 /MMBtu

TOTAL ENERGY

 6,006 MMBtu
3,084 MMBtu		 $ 42,751
$ 20,779		 5.90 %
2.87 %		 $ 6.93 /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		 APPLY FOR TAX-FREE STATUS FOR ENERGY PURCHASES 2.8121 I $ 0 $ 3,524 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

One-time Revenue or Avoided Cost

 - $ 3,524 -

TOTAL PRODUCTON

 - $ 3,524 -
02 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 0 $ 2,667 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,420 kWh $ 2,499 $ 0.063 /kWh

- Demand Charge

 54 kW $ 168 $ 3.12 /kW

TOTAL ENERGY

 404 MMBtu $ 2,667 -
03 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 I $ 380 $ 2,571 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 37,908 kWh $ 2,403 $ 0.063 /kWh

- Demand Charge

 54 kW $ 168 $ 3.12 /kW

TOTAL ENERGY

 389 MMBtu $ 2,571 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 312 $ 2,489 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,256 kWh $ 2,489 $ 0.063 /kWh

TOTAL ENERGY

 402 MMBtu $ 2,489 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 49 $ 1,458 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,998 kWh $ 1,458 $ 0.063 /kWh

TOTAL ENERGY

 236 MMBtu $ 1,458 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 1,756 $ 7,970 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 125,703 kWh $ 7,970 $ 0.063 /kWh

TOTAL ENERGY

 1,288 MMBtu $ 7,970 -
07 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 126 $ 295 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,927 kWh $ 122 $ 0.063 /kWh

- Demand Charge

 3 kW $ 8 $ 3.12 /kW

TOTAL ENERGY

 20 MMBtu $ 130 -

Personnel Changes

 - $ 101 -

One-time Revenue or Avoided Cost

 - $ 64 -

TOTAL PRODUCTON

 - $ 165 -
08 view
details		 REDUCE VENTILATION AIR 2.7314 I $ 2,297 $ 2,808 0.82
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,000 kWh $ 190 $ 0.063 /kWh

- Demand Charge

 12 kW $ 37 $ 3.12 /kW

Natural Gas

 333 MMBtu $ 2,581 $ 7.76 /MMBtu

TOTAL ENERGY

 364 MMBtu $ 2,808 -
09 view
details		 INSULATE GLAZING, WALLS, CEILINGS, AND ROOFS 2.7491 N $ 6,493 $ 3,531 1.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 455 MMBtu $ 3,531 $ 7.76 /MMBtu

TOTAL ENERGY

 455 MMBtu $ 3,531 -
10 view
details		 ELIMINATE/REDUCE AN OPERATION 3.1161 N $ 7,920 $ 2,679 2.96
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -656 kWh $ -42 $ 0.063 /kWh

- Demand Charge

 -198 kW $ -618 $ 3.12 /kW

TOTAL ENERGY

 -7 MMBtu $ -660 -

Personnel Changes

 - $ 418 -

One-time Revenue or Avoided Cost

 - $ 2,921 -

TOTAL PRODUCTON

 - $ 3,339 -
11 view
details		 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 2.6211 N $ 458 $ 90 5.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,419 kWh $ 90 $ 0.063 /kWh

TOTAL ENERGY

 15 MMBtu $ 90 -
12 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 23,409 $ 3,646 6.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 3,646 -

TOTAL ENERGY

 0 MMBtu $ 3,646 -
13 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 41,855 $ 6,370 6.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,832 kWh $ 116 $ 0.063 /kWh

- Demand Charge

 4 kW $ 11 $ 3.12 /kW

TOTAL ENERGY

 19 MMBtu $ 127 -

Personnel Changes

 - $ 1,026 -

One-time Revenue or Avoided Cost

 - $ 5,217 -

TOTAL PRODUCTON

 - $ 6,243 -
14 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 750 $ 11,240 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 177,431 kWh $ 11,249 $ 0.063 /kWh

- Demand Charge

 -3 kW $ -9 $ 3.12 /kW

TOTAL ENERGY

 1,819 MMBtu $ 11,240 -
15 view
details		 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 2.7243 I $ 3,784 $ 4,684 0.81
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -1,015 kWh $ -64 $ 0.063 /kWh

- Demand Charge

 -2 kW $ -7 $ 3.12 /kW

Natural Gas

 613 MMBtu $ 4,755 $ 7.76 /MMBtu

TOTAL ENERGY

 603 MMBtu $ 4,684 -