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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #TT0085


Assessment Year 2012
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Automotive Fuel Tanks
Sales $ 150,000,000
# of Employees 300
Plant Area (Sq.Ft.) 300,000
Annual Production 900,000 Pieces
Production Hrs. Annual 6,000
Location (State) TN
Yearly Energy Cost $ 2,153,498

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 25,722,000 kWh $ 1,512,333 $ 0.059 /kWh

- Demand Charge

 60,225 kW $ 707,867 $ 11.75 /kW

- Electricity Fees

 - $ -182,028 -

Natural Gas

 3,984 MMBtu $ 33,572 $ 8.43 /MMBtu

LPG

 35,981 MMBtu $ 81,754 $ 2.27 /MMBtu

TOTAL ENERGY

 303,619 MMBtu $ 2,153,498 $ 7.09 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,169,601 kWh
1,099,542 kWh		 $ 70,280
$ 64,873		 4.65 %
4.29 %		 $ 0.059 /kWh

- Demand Charge

 14,400 kW
2,238 kW		 $ 169,255
$ 26,303		 23.91 %
3.72 %		 $ 11.75 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 8.43 /MMBtu

LPG

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 2.27 /MMBtu

TOTAL ENERGY

 11,989 MMBtu
11,270 MMBtu		 $ 239,535
$ 91,176		 11.12 %
4.23 %		 $ 7.09 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 100,850 $ 142,952 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 12,162 kW $ 142,952 $ 11.75 /kW

TOTAL ENERGY

 0 MMBtu $ 142,952 -
02 view
details		 REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE 2.4131 N $ 1,700 $ 3,300 0.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,800 kWh $ 3,300 $ 0.059 /kWh

TOTAL ENERGY

 439 MMBtu $ 3,300 -
03 view
details		 REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE 2.4131 N $ 1,700 $ 1,900 0.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,500 kWh $ 1,900 $ 0.059 /kWh

TOTAL ENERGY

 251 MMBtu $ 1,900 -
04 view
details		 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 2.6211 N $ 20 $ 207 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,759 kWh $ 207 $ 0.059 /kWh

TOTAL ENERGY

 28 MMBtu $ 207 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 8,867 $ 4,813 1.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 52,722 kWh $ 3,111 $ 0.059 /kWh

- Demand Charge

 145 kW $ 1,702 $ 11.75 /kW

TOTAL ENERGY

 540 MMBtu $ 4,813 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 3,940 $ 2,203 1.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,700 kWh $ 1,575 $ 0.059 /kWh

- Demand Charge

 53 kW $ 628 $ 11.75 /kW

TOTAL ENERGY

 274 MMBtu $ 2,203 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 3,440 $ 421 8.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,100 kWh $ 301 $ 0.059 /kWh

- Demand Charge

 10 kW $ 120 $ 11.75 /kW

TOTAL ENERGY

 52 MMBtu $ 421 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,158 $ 312 13.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,780 kWh $ 223 $ 0.059 /kWh

- Demand Charge

 8 kW $ 89 $ 11.75 /kW

TOTAL ENERGY

 39 MMBtu $ 312 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 175,342 $ 83,427 2.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,011,240 kWh $ 59,663 $ 0.059 /kWh

- Demand Charge

 2,022 kW $ 23,764 $ 11.75 /kW

TOTAL ENERGY

 10,365 MMBtu $ 83,427 -