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

Industrial Assessment Centers

Assessment #TA0070


Assessment Year 2004
SIC 3089
SIC Description Plastics Products, Nec
NAICS 333511
NAICS Description Industrial Mold Manufacturing
Principal Product Plastic Products
Sales $ 24,000,000
# of Employees 180
Plant Area (Sq.Ft.) 130,000
Annual Production 325,000 Pieces
Production Hrs. Annual 6,288
Location (State) TX
Yearly Energy Cost $ 386,292

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 5,488,216 kWh $ 308,739 $ 0.056 /kWh

- Demand Charge

 12,466 kW $ 53,496 $ 4.29 /kW

- Electricity Fees

 - $ 24,057 -

TOTAL ENERGY

 56,254 MMBtu $ 386,292 $ 6.87 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 374,899 kWh
280,056 kWh		 $ 22,693
$ 16,955		 7.35 %
5.49 %		 $ 0.056 /kWh

- Demand Charge

 248 kW
134 kW		 $ 1,050
$ 570		 1.96 %
1.07 %		 $ 4.29 /kW

- Electricity Fees

 - $ 21,150
$ 21,150		 87.92 %
87.92 %		 -

TOTAL ENERGY

 3,843 MMBtu
2,871 MMBtu		 $ 44,893
$ 38,675		 11.62 %
10.01 %		 $ 6.87 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 2.8114 I $ 0 $ 43,350 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 43,350 -

TOTAL PRODUCTON

 - $ 43,350 -
02 view
details		 APPLY FOR TAX-FREE STATUS FOR ENERGY PURCHASES 2.8121 I $ -21,150 $ 21,150 -1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 21,150 -

TOTAL ENERGY

 0 MMBtu $ 21,150 -
03 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 7,300 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 120,600 kWh $ 7,300 $ 0.056 /kWh

TOTAL ENERGY

 1,236 MMBtu $ 7,300 -
04 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 590 $ 3,100 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,270 kWh $ 2,740 $ 0.056 /kWh

- Demand Charge

 86 kW $ 360 $ 4.29 /kW

TOTAL ENERGY

 464 MMBtu $ 3,100 -
05 view
details		 CLOSE HOLES AND OPENINGS IN BUILDING SUCH AS BROKEN WINDOWS 2.7444 I $ 130 $ 2,990 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 49,390 kWh $ 2,990 $ 0.056 /kWh

TOTAL ENERGY

 506 MMBtu $ 2,990 -
06 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 0 $ 2,650 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 37,964 kWh $ 2,300 $ 0.056 /kWh

- Demand Charge

 82 kW $ 350 $ 4.29 /kW

TOTAL ENERGY

 389 MMBtu $ 2,650 -
07 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 N $ 0 $ 2,088 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,483 kWh $ 2,088 $ 0.056 /kWh

TOTAL ENERGY

 353 MMBtu $ 2,088 -
08 view
details		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 I $ 410 $ 2,020 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,325 kWh $ 2,020 $ 0.056 /kWh

TOTAL ENERGY

 342 MMBtu $ 2,020 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 50 $ 1,885 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 27,489 kWh $ 1,665 $ 0.056 /kWh

- Demand Charge

 52 kW $ 220 $ 4.29 /kW

TOTAL ENERGY

 282 MMBtu $ 1,885 -
10 view
details		 DISCONNECT BALLASTS 2.7122 N $ 200 $ 1,030 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 15,090 kWh $ 910 $ 0.056 /kWh

- Demand Charge

 28 kW $ 120 $ 4.29 /kW

TOTAL ENERGY

 155 MMBtu $ 1,030 -
11 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 290 $ 680 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,288 kWh $ 680 $ 0.056 /kWh

TOTAL ENERGY

 116 MMBtu $ 680 -