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

Industrial Assessment Centers

Assessment #UD0769


Assessment Year 2007
SIC 3714
SIC Description Motor Vehicle Parts And Accessories
NAICS 336350
NAICS Description Motor Vehicle Transmission and Power Train Parts Manufacturing
Principal Product Power Transmission Components
Sales $ 110,000,000
# of Employees 652
Plant Area (Sq.Ft.) 432,573
Annual Production 290,000 Not Available
Production Hrs. Annual 7,200
Location (State) KY
Yearly Energy Cost $ 1,669,194

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 23,236,252 kWh $ 1,162,065 $ 0.050 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 40,996 MMBtu $ 507,129 $ 12.37 /MMBtu

TOTAL ENERGY

 279,168 MMBtu $ 1,669,194 $ 5.98 /MMBtu

Water Disposal

 5,124 Gal $ 24,794 $ 5 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 6,291,212 kWh
6,291,212 kWh		 $ 238,470
$ 238,470		 20.52 %
20.52 %		 $ 0.050 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 22,298 MMBtu
19,264 MMBtu		 $ 279,718
$ 238,615		 55.16 %
47.05 %		 $ 12.37 /MMBtu

TOTAL ENERGY

 86,783 MMBtu
83,749 MMBtu		 $ 547,548
$ 506,445		 32.80 %
30.34 %		 $ 5.98 /MMBtu

Water Disposal

 359,812 Gal
359,812 Gal		 $ 1,800
$ 1,800		 7.26 %
7.26 %		 $ 5 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 126,798 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,345,602 kWh $ 126,798 $ 0.050 /kWh

TOTAL ENERGY

 34,292 MMBtu $ 126,798 -
02 view
details		 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 2.6221 I $ 0 $ 119,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 9,600 MMBtu $ 119,000 $ 12.37 /MMBtu

TOTAL ENERGY

 9,600 MMBtu $ 119,000 -
03 view
details		 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 2.7121 I $ 110,000 $ 63,509 1.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,181,613 kWh $ 44,783 $ 0.050 /kWh

- Demand Charge

 141 kW $ 13,062 $ 0.00 /kW

TOTAL ENERGY

 12,112 MMBtu $ 57,845 -

Administrative Changes

 - $ 5,664 -

TOTAL PRODUCTON

 - $ 5,664 -
04 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 110,000 $ 61,170 1.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,123,200 kWh $ 42,569 $ 0.050 /kWh

- Demand Charge

 156 kW $ 14,452 $ 0.00 /kW

TOTAL ENERGY

 11,513 MMBtu $ 57,021 -

Administrative Changes

 - $ 4,149 -

TOTAL PRODUCTON

 - $ 4,149 -
05 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 I $ 28,125 $ 44,667 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,600 MMBtu $ 44,667 $ 12.37 /MMBtu

TOTAL ENERGY

 3,600 MMBtu $ 44,667 -
06 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 I $ 130,000 $ 39,200 3.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,150 MMBtu $ 39,200 $ 12.37 /MMBtu

TOTAL ENERGY

 3,150 MMBtu $ 39,200 -
07 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 25,268 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 334,731 kWh $ 12,720 $ 0.050 /kWh

Natural Gas

 1,014 MMBtu $ 12,548 $ 12.37 /MMBtu

TOTAL ENERGY

 4,445 MMBtu $ 25,268 -
08 view
details		 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 2.1113 I $ 400 $ 23,200 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,900 MMBtu $ 23,200 $ 12.37 /MMBtu

TOTAL ENERGY

 1,900 MMBtu $ 23,200 -
09 view
details		 REDUCE COMBUSTION AIR FLOW TO OPTIMUM 2.1113 N $ 600 $ 13,400 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,080 MMBtu $ 13,400 $ 12.37 /MMBtu

TOTAL ENERGY

 1,080 MMBtu $ 13,400 -
10 view
details		 USE HEAT IN FLUE GASES TO PREHEAT PRODUCTS OR MATERIALS 2.2424 N $ 25,000 $ 10,000 2.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 810 MMBtu $ 10,000 $ 12.37 /MMBtu

TOTAL ENERGY

 810 MMBtu $ 10,000 -
11 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 3,275 $ 4,569 0.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 90,000 kWh $ 3,411 $ 0.050 /kWh

- Demand Charge

 13 kW $ 1,158 $ 0.00 /kW

TOTAL ENERGY

 923 MMBtu $ 4,569 -
12 view
details		 REDUCE VENTILATION AIR 2.7314 N $ 26,910 $ 17,703 1.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,144 MMBtu $ 17,703 $ 12.37 /MMBtu

TOTAL ENERGY

 1,144 MMBtu $ 17,703 -
13 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 0 $ 3,980 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 105,000 kWh $ 3,980 $ 0.050 /kWh

TOTAL ENERGY

 1,076 MMBtu $ 3,980 -
14 view
details		 REDUCE VENTILATION AIR 2.7314 I $ 590 $ 2,208 0.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,254 kWh $ 2,208 $ 0.050 /kWh

TOTAL ENERGY

 597 MMBtu $ 2,208 -
15 view
details		 METER RECYCLED WATER (TO REDUCE SEWER CHARGES) 3.4116 I $ 500 $ 1,800 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 359,812 Gal $ 1,800 $ 5 /Gal

TOTAL WASTE

 - $ 1,800 -
16 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 520 $ 1,447 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,512 kWh $ 1,080 $ 0.050 /kWh

- Demand Charge

 4 kW $ 367 $ 0.00 /kW

TOTAL ENERGY

 292 MMBtu $ 1,447 -
17 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 1,242 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,300 kWh $ 921 $ 0.050 /kWh

- Demand Charge

 3 kW $ 321 $ 0.00 /kW

TOTAL ENERGY

 249 MMBtu $ 1,242 -