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

Industrial Assessment Centers

Assessment #UD0679


Assessment Year 2003
SIC 3411
SIC Description Metal Cans
NAICS 332431
NAICS Description Metal Can Manufacturing
Principal Product Aluminum beverage cans
Sales $ 110,000,000
# of Employees 118
Plant Area (Sq.Ft.) 249,500
Annual Production 2,100,000,000 Pieces
Production Hrs. Annual 8,568
Location (State) OH
Yearly Energy Cost $ 2,145,067

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 35,683,200 kWh $ 767,189 $ 0.022 /kWh

- Demand Charge

 54,384 kW $ 616,770 $ 11.34 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 148,860 MMBtu $ 761,108 $ 5.11 /MMBtu

TOTAL ENERGY

 514,613 MMBtu $ 2,145,067 $ 4.17 /MMBtu

Water Disposal

 23,227,800 Gal $ 99,215 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 2,620,228 kWh
0 kWh		 $ 57,658
$ 0		 7.52 %
0.00 %		 $ 0.022 /kWh

- Demand Charge

 3,511 kW
0 kW		 $ 45,374
$ 0		 7.36 %
0.00 %		 $ 11.34 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 46,121 MMBtu
0 MMBtu		 $ 235,678
$ 0		 30.97 %
0.00 %		 $ 5.11 /MMBtu

TOTAL ENERGY

 72,977 MMBtu
0 MMBtu		 $ 338,710
$ 0		 15.79 %
0.00 %		 $ 4.17 /MMBtu

Water Disposal

 5,185,830 Gal
0 Gal		 $ 12,046
$ 0		 12.14 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE BUILDING VENTILATION AIR TO MINIMUM SAFE LEVELS 2.7315 K $ -3,800,000 $ 241,706 -15.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 160,600 kWh $ 3,533 $ 0.022 /kWh

- Demand Charge

 220 kW $ 2,495 $ 11.34 /kW

Natural Gas

 46,121 MMBtu $ 235,678 $ 5.11 /MMBtu

TOTAL ENERGY

 47,767 MMBtu $ 241,706 -
02 view
details		 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 2.2614 K $ 1,125 $ 52,385 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,405,980 kWh $ 30,932 $ 0.022 /kWh

- Demand Charge

 1,836 kW $ 21,841 $ 11.34 /kW

TOTAL ENERGY

 14,411 MMBtu $ 52,773 -

Personnel Changes

 - $ -388 -

TOTAL PRODUCTON

 - $ -388 -
03 view
details		 METER RECYCLED WATER (TO REDUCE SEWER CHARGES) 3.4116 K $ 270 $ 12,046 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 5,185,830 Gal $ 12,046 $ 0 /Gal

TOTAL WASTE

 - $ 12,046 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 K $ 1,100 $ 12,330 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 205,600 kWh $ 4,530 $ 0.022 /kWh

- Demand Charge

 288 kW $ 7,800 $ 11.34 /kW

TOTAL ENERGY

 2,107 MMBtu $ 12,330 -
05 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 K $ 200 $ 7,465 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 197,000 kWh $ 4,335 $ 0.022 /kWh

- Demand Charge

 276 kW $ 3,130 $ 11.34 /kW

TOTAL ENERGY

 2,019 MMBtu $ 7,465 -
06 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 K $ 0 $ 7,398 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 197,100 kWh $ 4,336 $ 0.022 /kWh

- Demand Charge

 270 kW $ 3,062 $ 11.34 /kW

TOTAL ENERGY

 2,020 MMBtu $ 7,398 -
07 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 K $ 7,100 $ 6,070 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 160,222 kWh $ 3,525 $ 0.022 /kWh

- Demand Charge

 224 kW $ 2,545 $ 11.34 /kW

TOTAL ENERGY

 1,642 MMBtu $ 6,070 -
08 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 K $ 1,750 $ 5,200 0.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 137,000 kWh $ 3,020 $ 0.022 /kWh

- Demand Charge

 192 kW $ 2,180 $ 11.34 /kW

TOTAL ENERGY

 1,404 MMBtu $ 5,200 -
09 view
details		 DISCONNECT BALLASTS 2.7122 K $ 132 $ 3,797 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 100,245 kWh $ 2,205 $ 0.022 /kWh

- Demand Charge

 140 kW $ 1,592 $ 11.34 /kW

TOTAL ENERGY

 1,028 MMBtu $ 3,797 -
10 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 K $ 3,618 $ 1,739 2.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,930 kWh $ 1,010 $ 0.022 /kWh

- Demand Charge

 65 kW $ 729 $ 11.34 /kW

TOTAL ENERGY

 471 MMBtu $ 1,739 -
11 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 K $ 110 $ 232 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,551 kWh $ 232 $ 0.022 /kWh

TOTAL ENERGY

 108 MMBtu $ 232 -