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

Industrial Assessment Centers

Assessment #UD0730


Assessment Year 2005
SIC 3965
SIC Description Fasteners, Buttons, Needles, & Pins
NAICS 339993
NAICS Description Fastener, Button, Needle, and Pin Manufacturing
Principal Product Caddy Fasteners
Sales $ 17,000,000
# of Employees 224
Plant Area (Sq.Ft.) 170,000
Annual Production 336,000,000 Pieces
Production Hrs. Annual 6,240
Location (State) Oh
Yearly Energy Cost $ 858,270

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,080,813 kWh $ 311,251 $ 0.051 /kWh

- Demand Charge

 11,604 kW $ 160,822 $ 13.86 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 41,720 MMBtu $ 386,197 $ 9.26 /MMBtu

TOTAL ENERGY

 104,048 MMBtu $ 858,270 $ 8.25 /MMBtu

Water Disposal

 5,563,620 Gal $ 47,298 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,019,346 kWh
122,405 kWh		 $ 19,328
$ 2,325		 6.21 %
0.75 %		 $ 0.051 /kWh

- Demand Charge

 2,003 kW
299 kW		 $ 61,260
$ 9,123		 38.09 %
5.67 %		 $ 13.86 /kW

- Electricity Fees

 - $ 3,480
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 4,503 MMBtu
699 MMBtu		 $ 41,698
$ 6,473		 10.80 %
1.68 %		 $ 9.26 /MMBtu

TOTAL ENERGY

 14,952 MMBtu
1,954 MMBtu		 $ 125,766
$ 17,921		 14.65 %
2.09 %		 $ 8.25 /MMBtu

Water Disposal

 110,719 Gal
0 Gal		 $ 939
$ 0		 1.99 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 3,600 $ 40,357 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 519,920 kWh $ 9,840 $ 0.051 /kWh

- Demand Charge

 996 kW $ 30,517 $ 13.86 /kW

TOTAL ENERGY

 5,329 MMBtu $ 40,357 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 7,200 $ 29,475 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 366,912 kWh $ 6,971 $ 0.051 /kWh

- Demand Charge

 708 kW $ 21,620 $ 13.86 /kW

TOTAL ENERGY

 3,761 MMBtu $ 28,591 -

Ancillary Material Cost

 - $ 884 -

TOTAL PRODUCTON

 - $ 884 -
03 view
details		 MINIMIZE NON-ESSENTIAL MATERIAL IN HEAT TREATMENT PROCESS 2.2312 N $ 25,000 $ 13,381 1.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,445 MMBtu $ 13,381 $ 9.26 /MMBtu

TOTAL ENERGY

 1,445 MMBtu $ 13,381 -
04 view
details		 COVER OPEN TANKS WITH FLOATING INSULATION 2.2513 N $ 2,170 $ 12,069 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,204 MMBtu $ 11,149 $ 9.26 /MMBtu

TOTAL ENERGY

 1,204 MMBtu $ 11,149 -

Water Disposal

 108,475 Gal $ 920 $ 0 /Gal

TOTAL WASTE

 - $ 920 -
05 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 I $ 12,880 $ 6,473 1.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 699 MMBtu $ 6,473 $ 9.26 /MMBtu

TOTAL ENERGY

 699 MMBtu $ 6,473 -
06 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 4,350 $ 5,769 0.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 623 MMBtu $ 5,769 $ 9.26 /MMBtu

TOTAL ENERGY

 623 MMBtu $ 5,769 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 4,376 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 56,160 kWh $ 1,067 $ 0.051 /kWh

- Demand Charge

 108 kW $ 3,309 $ 13.86 /kW

TOTAL ENERGY

 576 MMBtu $ 4,376 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 9,916 $ 4,232 2.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 30,925 kWh $ 588 $ 0.051 /kWh

- Demand Charge

 120 kW $ 3,644 $ 13.86 /kW

TOTAL ENERGY

 317 MMBtu $ 4,232 -
09 view
details		 USE PLANT OWNED TRANSFORMERS OR LEASE TRANSFORMERS 2.3511 N $ 1,500 $ 3,480 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 3,480 -

TOTAL ENERGY

 0 MMBtu $ 3,480 -
10 view
details		 USE MINIMUM SAFE OVEN VENTILATION 2.2212 N $ 150 $ 3,222 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 348 MMBtu $ 3,222 $ 9.26 /MMBtu

TOTAL ENERGY

 348 MMBtu $ 3,222 -
11 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 945 $ 2,840 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,320 kWh $ 670 $ 0.051 /kWh

- Demand Charge

 71 kW $ 2,170 $ 13.86 /kW

TOTAL ENERGY

 362 MMBtu $ 2,840 -
12 view
details		 REDUCE VENTILATION AIR 2.7314 N $ 0 $ 1,408 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 152 MMBtu $ 1,408 $ 9.26 /MMBtu

TOTAL ENERGY

 152 MMBtu $ 1,408 -
13 view
details		 COVER OPEN TANKS 2.2514 N $ 0 $ 315 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 32 MMBtu $ 296 $ 9.26 /MMBtu

TOTAL ENERGY

 32 MMBtu $ 296 -

Water Disposal

 2,244 Gal $ 19 $ 0 /Gal

TOTAL WASTE

 - $ 19 -
14 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 600 $ 192 3.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,109 kWh $ 192 $ 0.051 /kWh

TOTAL ENERGY

 104 MMBtu $ 192 -