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

Industrial Assessment Centers

Assessment #UD0723


Assessment Year 2005
SIC 3052
SIC Description Rubber & Plastics Hose & Belting
NAICS 326220
NAICS Description Rubber and Plastics Hoses and Belting Manufacturing
Principal Product Fluid moving systems
Sales $ 65,000,000
# of Employees 450
Plant Area (Sq.Ft.) 110,000
Annual Production 26,000,000 Pieces
Production Hrs. Annual 7,200
Location (State) IN
Yearly Energy Cost $ 568,641

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,580,083 kWh $ 211,034 $ 0.028 /kWh

- Demand Charge

 16,920 kW $ 163,830 $ 9.68 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 26,401 MMBtu $ 193,777 $ 7.34 /MMBtu

TOTAL ENERGY

 104,097 MMBtu $ 568,641 $ 5.46 /MMBtu

Water Disposal

 14,873,724 Gal $ 83,002 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,160,333 kWh
999,973 kWh		 $ 32,076
$ 28,062		 15.20 %
13.30 %		 $ 0.028 /kWh

- Demand Charge

 2,596 kW
1,532 kW		 $ 21,959
$ 14,860		 13.40 %
9.07 %		 $ 9.68 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,578 MMBtu
1,571 MMBtu		 $ 18,926
$ 11,532		 9.77 %
5.95 %		 $ 7.34 /MMBtu

TOTAL ENERGY

 14,471 MMBtu
11,821 MMBtu		 $ 72,961
$ 54,454		 12.83 %
9.58 %		 $ 5.46 /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		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 65,105 $ 24,840 2.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 503,320 kWh $ 12,580 $ 0.028 /kWh

- Demand Charge

 840 kW $ 8,150 $ 9.68 /kW

TOTAL ENERGY

 5,159 MMBtu $ 20,730 -

Ancillary Material Cost

 - $ 4,110 -

TOTAL PRODUCTON

 - $ 4,110 -
02 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 I $ 0 $ 7,430 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 166,850 kWh $ 4,170 $ 0.028 /kWh

- Demand Charge

 336 kW $ 3,260 $ 9.68 /kW

TOTAL ENERGY

 1,710 MMBtu $ 7,430 -
03 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 0 $ 7,394 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,007 MMBtu $ 7,394 $ 7.34 /MMBtu

TOTAL ENERGY

 1,007 MMBtu $ 7,394 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 13,340 $ 6,315 2.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 133,848 kWh $ 3,350 $ 0.028 /kWh

- Demand Charge

 268 kW $ 2,600 $ 9.68 /kW

TOTAL ENERGY

 1,372 MMBtu $ 5,950 -

Ancillary Material Cost

 - $ 365 -

TOTAL PRODUCTON

 - $ 365 -
05 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 I $ 7,000 $ 6,126 1.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 122,515 kWh $ 6,126 $ 0.028 /kWh

TOTAL ENERGY

 1,256 MMBtu $ 6,126 -
06 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 0 $ 5,470 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 564 kW $ 5,470 $ 9.68 /kW

TOTAL ENERGY

 0 MMBtu $ 5,470 -
07 view
details		 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC 2.1131 I $ 0 $ 4,573 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 623 MMBtu $ 4,573 $ 7.34 /MMBtu

TOTAL ENERGY

 623 MMBtu $ 4,573 -
08 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 0 $ 4,309 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 587 MMBtu $ 4,309 $ 7.34 /MMBtu

TOTAL ENERGY

 587 MMBtu $ 4,309 -
09 view
details		 REDUCE WATER USE WITH COUNTER CURRENT RINSING 3.1222 N $ 2,000 $ 3,070 0.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,000 kWh $ 650 $ 0.028 /kWh

TOTAL ENERGY

 267 MMBtu $ 650 -

Other Liquid (non-haz)

 431,654 Gal $ 2,420 $ 0 /Gal

TOTAL WASTE

 - $ 2,420 -
10 view
details		 USE PROPERLY DESIGNED AND SIZED HVAC EQUIPMENT 2.7233 N $ 0 $ 2,730 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 66,200 kWh $ 1,660 $ 0.028 /kWh

- Demand Charge

 442 kW $ 1,070 $ 9.68 /kW

TOTAL ENERGY

 679 MMBtu $ 2,730 -
11 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 2,629 $ 2,650 0.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 361 MMBtu $ 2,650 $ 7.34 /MMBtu

TOTAL ENERGY

 361 MMBtu $ 2,650 -
12 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 2,164 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 52,560 kWh $ 1,314 $ 0.028 /kWh

- Demand Charge

 88 kW $ 850 $ 9.68 /kW

TOTAL ENERGY

 539 MMBtu $ 2,164 -
13 view
details		 REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE 2.4131 N $ 500 $ 1,423 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,560 kWh $ 864 $ 0.028 /kWh

- Demand Charge

 58 kW $ 559 $ 9.68 /kW

TOTAL ENERGY

 354 MMBtu $ 1,423 -
14 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 N $ 0 $ 840 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,600 kWh $ 840 $ 0.028 /kWh

TOTAL ENERGY

 344 MMBtu $ 840 -
15 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 0 $ 522 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,880 kWh $ 522 $ 0.028 /kWh

TOTAL ENERGY

 214 MMBtu $ 522 -