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

Industrial Assessment Centers

Assessment #UD0610


Assessment Year 2001
SIC 3562
SIC Description Ball And Roller Bearings
NAICS
NAICS Description
Principal Product Ball Bearings
Sales $ 50,000,000
# of Employees 419
Plant Area (Sq.Ft.) 160,000
Annual Production 7,000,000 Pounds
Production Hrs. Annual 6,174
Location (State) IN
Yearly Energy Cost $ 570,289

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,360,199 kWh $ 170,491 $ 0.016 /kWh

- Demand Charge

 20,724 kW $ 221,954 $ 10.71 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 47,186 MMBtu $ 177,844 $ 3.77 /MMBtu

TOTAL ENERGY

 153,378 MMBtu $ 570,289 $ 3.72 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 -249,414 kWh
-587,046 kWh		 $ -16,541
$ -22,614		 -9.70 %
-13.26 %		 $ 0.016 /kWh

- Demand Charge

 451 kW
0 kW		 $ 4,833
$ 0		 2.18 %
0.00 %		 $ 10.71 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 675 MMBtu
307 MMBtu		 $ 2,521
$ 1,134		 1.42 %
0.64 %		 $ 3.77 /MMBtu

TOTAL ENERGY

 -1,882 MMBtu
-5,710 MMBtu		 $ -9,187
$ -21,480		 -1.61 %
-3.77 %		 $ 3.72 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 IMPROVE SPACE COMFORT CONDITIONING 4.4240 I $ 402,000 $ 101,536 3.96
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -634,232 kWh $ -23,464 $ 0.016 /kWh

TOTAL ENERGY

 -6,501 MMBtu $ -23,464 -

Primary Product

 - $ 125,000 -

TOTAL PRODUCTON

 - $ 125,000 -
02 view
details		 USE LESS TOXIC AND VOLATILE SOLVENT SUBSTITUTES 3.8132 N $ 2,550 $ 95,666 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (haz)

 261,196 Gal $ 15,333 $ 0 /Gal

TOTAL WASTE

 - $ 15,333 -

Administrative Changes

 - $ 80,333 -

TOTAL PRODUCTON

 - $ 80,333 -
03 view
details		 USE FIXTURES TO REDUCE MACHINE CHANGEOUT TIMES 4.6210 N $ 12,000 $ 28,005 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 28,005 -

TOTAL PRODUCTON

 - $ 28,005 -
04 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 1,500 $ 2,646 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 147,128 kWh $ 2,646 $ 0.016 /kWh

TOTAL ENERGY

 1,508 MMBtu $ 2,646 -
05 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 0 $ 6,232 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 160,610 kWh $ 2,890 $ 0.016 /kWh

- Demand Charge

 312 kW $ 3,342 $ 10.71 /kW

TOTAL ENERGY

 1,646 MMBtu $ 6,232 -
06 view
details		 USE SEPARATE SWITCHES ON PERIMETER LIGHTING WHICH MAY BE TURNED OFF WHEN NATURAL LIGHT IS AVAILABLE 2.7133 N $ 0 $ 2,028 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,894 kWh $ 537 $ 0.016 /kWh

- Demand Charge

 139 kW $ 1,491 $ 10.71 /kW

TOTAL ENERGY

 306 MMBtu $ 2,028 -
07 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 6,000 $ 1,984 3.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,186 kWh $ 850 $ 0.016 /kWh

Natural Gas

 307 MMBtu $ 1,134 $ 3.77 /MMBtu

TOTAL ENERGY

 791 MMBtu $ 1,984 -
08 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT INCOMING FLUIDS 2.2427 N $ 500 $ 1,387 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 368 MMBtu $ 1,387 $ 3.77 /MMBtu

TOTAL ENERGY

 368 MMBtu $ 1,387 -