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

Industrial Assessment Centers

Assessment #TT0090


Assessment Year 2012
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Engineered Fiberglass Panel
Sales $ 49,000,000
# of Employees 80
Plant Area (Sq.Ft.) 125,000
Annual Production 48,000 Thousand Feet
Production Hrs. Annual 6,000
Location (State) AR
Yearly Energy Cost $ 414,832

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,714,000 kWh $ 191,349 $ 0.029 /kWh

- Demand Charge

 16,990 kW $ 75,606 $ 4.45 /kW

- Electricity Fees

 - $ 3,769 -

Natural Gas

 31,313 MMBtu $ 144,108 $ 4.60 /MMBtu

TOTAL ENERGY

 100,132 MMBtu $ 414,832 $ 4.14 /MMBtu

Water Disposal

 26,105,000 Gal $ 6,254 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 911,018 kWh
276,302 kWh		 $ 25,954
$ 7,865		 13.56 %
4.11 %		 $ 0.029 /kWh

- Demand Charge

 854 kW
0 kW		 $ 3,800
$ 0		 5.03 %
0.00 %		 $ 4.45 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 6,350 MMBtu
0 MMBtu		 $ 29,200
$ 0		 20.26 %
0.00 %		 $ 4.60 /MMBtu

TOTAL ENERGY

 15,688 MMBtu
2,832 MMBtu		 $ 58,954
$ 7,865		 14.21 %
1.90 %		 $ 4.14 /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		 RECOVER HEAT FROM TRANSFORMERS 2.2431 N $ 0 $ 4,085 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 143,350 kWh $ 4,085 $ 0.029 /kWh

TOTAL ENERGY

 1,469 MMBtu $ 4,085 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 0 $ 334 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,700 kWh $ 334 $ 0.029 /kWh

TOTAL ENERGY

 120 MMBtu $ 334 -
03 view
details		 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 2.6221 I $ 1,000 $ 1,275 0.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 44,720 kWh $ 1,275 $ 0.029 /kWh

TOTAL ENERGY

 458 MMBtu $ 1,275 -
04 view
details		 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 2.2614 I $ 2,000 $ 2,764 0.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 96,992 kWh $ 2,764 $ 0.029 /kWh

TOTAL ENERGY

 994 MMBtu $ 2,764 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 1,780 $ 1,008 1.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 36,000 kWh $ 1,008 $ 0.029 /kWh

TOTAL ENERGY

 369 MMBtu $ 1,008 -
06 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 35,000 $ 29,200 1.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,350 MMBtu $ 29,200 $ 4.60 /MMBtu

TOTAL ENERGY

 6,350 MMBtu $ 29,200 -
07 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 7,225 $ 3,800 1.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 854 kW $ 3,800 $ 4.45 /kW

TOTAL ENERGY

 0 MMBtu $ 3,800 -
08 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 2,400 $ 2,350 1.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 82,200 kWh $ 2,350 $ 0.029 /kWh

TOTAL ENERGY

 843 MMBtu $ 2,350 -
09 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 525 $ 134 3.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,690 kWh $ 134 $ 0.029 /kWh

TOTAL ENERGY

 48 MMBtu $ 134 -
10 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 54,507 $ 14,004 3.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 491,366 kWh $ 14,004 $ 0.029 /kWh

TOTAL ENERGY

 5,037 MMBtu $ 14,004 -