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

Industrial Assessment Centers

Assessment #UD0701


Assessment Year 2004
SIC 2022
SIC Description Cheese, Natural And Processed
NAICS 311513
NAICS Description Cheese Manufacturing
Principal Product Gelatin Based Desserts and Dairy Dips
Sales $ 35,000,000
# of Employees 168
Plant Area (Sq.Ft.) 60,000
Annual Production 40,000,000 Pounds
Production Hrs. Annual 6,240
Location (State) OH
Yearly Energy Cost $ 364,452

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,093,954 kWh $ 93,351 $ 0.023 /kWh

- Demand Charge

 9,132 kW $ 110,276 $ 12.08 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 21,394 MMBtu $ 160,825 $ 7.52 /MMBtu

TOTAL ENERGY

 63,357 MMBtu $ 364,452 $ 5.75 /MMBtu

Water Disposal

 40 Gal $ 218,621 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 293,703 kWh
0 kWh		 $ 6,801
$ 0		 7.29 %
0.00 %		 $ 0.023 /kWh

- Demand Charge

 598 kW
0 kW		 $ 7,334
$ 0		 6.65 %
0.00 %		 $ 12.08 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 3,679 MMBtu
0 MMBtu		 $ 27,664
$ 0		 17.20 %
0.00 %		 $ 7.52 /MMBtu

TOTAL ENERGY

 6,689 MMBtu
0 MMBtu		 $ 41,799
$ 0		 11.47 %
0.00 %		 $ 5.75 /MMBtu

Water Disposal

 19 Gal
0 Gal		 $ 97,494
$ 0		 44.59 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE OR ELIMINATE WASTE 3.7214 N $ 19,600 $ 85,956 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 202,800 lbs $ 34,476 $ 0 /lbs

TOTAL WASTE

 - $ 34,476 -

Personnel Changes

 - $ 51,480 -

TOTAL PRODUCTON

 - $ 51,480 -
02 view
details		 REDUCE EXCESSIVE BOILER BLOWDOWN 2.1241 N $ 1,619 $ 55,242 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 10 Gal $ 42,529 $ 0 /Gal

TOTAL WASTE

 - $ 42,529 -

Water Consumption

 - $ 12,713 -

TOTAL PRODUCTON

 - $ 12,713 -
03 view
details		 METER WASTE WATER 3.4155 N $ 15,700 $ 51,851 0.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 8 Gal $ 51,851 $ 0 /Gal

TOTAL WASTE

 - $ 51,851 -
04 view
details		 REDUCE OR ELIMINATE WASTE 3.7214 N $ 620 $ 38,220 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 249,600 lbs $ 37,440 $ 0 /lbs

TOTAL WASTE

 - $ 37,440 -

Personnel Changes

 - $ 780 -

TOTAL PRODUCTON

 - $ 780 -
05 view
details		 REDUCE VENTILATION AIR 2.7314 N $ 31,250 $ 22,847 1.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -46,800 kWh $ -1,030 $ 0.023 /kWh

- Demand Charge

 -90 kW $ -1,123 $ 12.08 /kW

TOTAL ENERGY

 -480 MMBtu $ -2,153 -

One-time Revenue or Avoided Cost

 - $ 25,000 -

TOTAL PRODUCTON

 - $ 25,000 -
06 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 N $ 1,500 $ 8,494 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 154,440 kWh $ 3,552 $ 0.023 /kWh

- Demand Charge

 396 kW $ 4,942 $ 12.08 /kW

TOTAL ENERGY

 1,583 MMBtu $ 8,494 -
07 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 16,000 $ 7,577 2.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,008 MMBtu $ 7,577 $ 7.52 /MMBtu

TOTAL ENERGY

 1,008 MMBtu $ 7,577 -
08 view
details		 REDUCE EXCESSIVE BOILER BLOWDOWN 2.1241 N $ 4,000 $ 6,179 0.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 721 MMBtu $ 5,422 $ 7.52 /MMBtu

TOTAL ENERGY

 721 MMBtu $ 5,422 -

Water Disposal

 0 Gal $ 584 $ 0 /Gal

TOTAL WASTE

 - $ 584 -

Water Consumption

 - $ 173 -

TOTAL PRODUCTON

 - $ 173 -
09 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 0 $ 5,926 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 788 MMBtu $ 5,926 $ 7.52 /MMBtu

TOTAL ENERGY

 788 MMBtu $ 5,926 -
10 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 4,800 $ 5,896 0.81
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 784 MMBtu $ 5,896 $ 7.52 /MMBtu

TOTAL ENERGY

 784 MMBtu $ 5,896 -
11 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 N $ 146 $ 5,373 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 378 MMBtu $ 2,843 $ 7.52 /MMBtu

TOTAL ENERGY

 378 MMBtu $ 2,843 -

Water Disposal

 0 Gal $ 2,530 $ 0 /Gal

TOTAL WASTE

 - $ 2,530 -
12 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 16,140 $ 5,315 3.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 134,352 kWh $ 3,090 $ 0.023 /kWh

- Demand Charge

 185 kW $ 2,225 $ 12.08 /kW

TOTAL ENERGY

 1,377 MMBtu $ 5,315 -
13 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 3,294 $ 1,444 2.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,400 kWh $ 722 $ 0.023 /kWh

- Demand Charge

 60 kW $ 722 $ 12.08 /kW

TOTAL ENERGY

 322 MMBtu $ 1,444 -
14 view
details		 DISCONNECT BALLASTS 2.7122 N $ 30 $ 397 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,611 kWh $ 198 $ 0.023 /kWh

- Demand Charge

 17 kW $ 199 $ 12.08 /kW

TOTAL ENERGY

 88 MMBtu $ 397 -
15 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 174 $ 386 0.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,020 kWh $ 161 $ 0.023 /kWh

- Demand Charge

 18 kW $ 225 $ 12.08 /kW

TOTAL ENERGY

 72 MMBtu $ 386 -
16 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 125 $ 261 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,680 kWh $ 108 $ 0.023 /kWh

- Demand Charge

 12 kW $ 144 $ 12.08 /kW

TOTAL ENERGY

 48 MMBtu $ 252 -

One-time Revenue or Avoided Cost

 - $ 9 -

TOTAL PRODUCTON

 - $ 9 -