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

Industrial Assessment Centers

Assessment #UD0778


Assessment Year 2008
SIC 2752
SIC Description Commercial Printing, Lithographic
NAICS 323110
NAICS Description Commercial Lithographic Printing
Principal Product Printing
Sales $ 80,000,000
# of Employees 400
Plant Area (Sq.Ft.) 200,200
Annual Production 350,094,386 Not Available
Production Hrs. Annual 7,200
Location (State) Ky
Yearly Energy Cost $ 1,267,727

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 14,696,896 kWh $ 996,489 $ 0.068 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 25,311 MMBtu $ 271,238 $ 10.72 /MMBtu

TOTAL ENERGY

 175,954 MMBtu $ 1,267,727 $ 7.20 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 649,826 kWh
97,671 kWh		 $ 28,806
$ 4,080		 2.89 %
0.41 %		 $ 0.068 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 7,753 MMBtu
0 MMBtu		 $ 83,113
$ 0		 30.64 %
0.00 %		 $ 10.72 /MMBtu

TOTAL ENERGY

 14,413 MMBtu
1,001 MMBtu		 $ 121,828
$ 5,422		 9.61 %
0.43 %		 $ 7.20 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RECOVER HEAT FROM OVEN EXHAUST / KILNS 2.2432 N $ 80,770 $ 77,393 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 7,219 MMBtu $ 77,393 $ 10.72 /MMBtu

TOTAL ENERGY

 7,219 MMBtu $ 77,393 -
02 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 12,000 $ 10,780 1.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 172,800 kWh $ 6,912 $ 0.068 /kWh

- Demand Charge

 24 kW $ 3,868 $ 0.00 /kW

TOTAL ENERGY

 1,771 MMBtu $ 10,780 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 22,560 $ 6,222 3.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 89,549 kWh $ 6,222 $ 0.068 /kWh

TOTAL ENERGY

 918 MMBtu $ 6,222 -
04 view
details		 REPLACE AIR CURTAIN DOORS WITH SOLID DOORS 2.2533 N $ 18,000 $ 5,905 3.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,139 kWh $ 126 $ 0.068 /kWh

- Demand Charge

 2 kW $ 59 $ 0.00 /kW

Natural Gas

 534 MMBtu $ 5,720 $ 10.72 /MMBtu

TOTAL ENERGY

 566 MMBtu $ 5,905 -
05 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 0 $ 3,783 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,320 kWh $ 2,333 $ 0.068 /kWh

- Demand Charge

 9 kW $ 1,450 $ 0.00 /kW

TOTAL ENERGY

 598 MMBtu $ 3,783 -
06 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 6,000 $ 3,431 1.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 85,787 kWh $ 3,431 $ 0.068 /kWh

TOTAL ENERGY

 879 MMBtu $ 3,431 -
07 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 2,176 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,876 kWh $ 1,395 $ 0.068 /kWh

- Demand Charge

 5 kW $ 781 $ 0.00 /kW

TOTAL ENERGY

 357 MMBtu $ 2,176 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 6,075 $ 1,563 3.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,056 kWh $ 1,002 $ 0.068 /kWh

- Demand Charge

 3 kW $ 561 $ 0.00 /kW

TOTAL ENERGY

 257 MMBtu $ 1,563 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 5,992 $ 6,692 0.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 107,280 kWh $ 4,291 $ 0.068 /kWh

- Demand Charge

 15 kW $ 2,401 $ 0.00 /kW

TOTAL ENERGY

 1,100 MMBtu $ 6,692 -
10 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 4,305 $ 1,683 2.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 37,739 kWh $ 1,683 $ 0.068 /kWh

TOTAL ENERGY

 387 MMBtu $ 1,683 -
11 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 1,302 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,880 kWh $ 835 $ 0.068 /kWh

- Demand Charge

 3 kW $ 467 $ 0.00 /kW

TOTAL ENERGY

 214 MMBtu $ 1,302 -
12 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 310 $ 853 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,680 kWh $ 547 $ 0.068 /kWh

- Demand Charge

 2 kW $ 306 $ 0.00 /kW

TOTAL ENERGY

 140 MMBtu $ 853 -
13 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 45 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 720 kWh $ 29 $ 0.068 /kWh

- Demand Charge

 0 kW $ 16 $ 0.00 /kW

TOTAL ENERGY

 7 MMBtu $ 45 -