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

Industrial Assessment Centers

Assessment #UD0791


Assessment Year 2009
SIC 3069
SIC Description Fabricated Rubber Products, Nec
NAICS 326192
NAICS Description Resilient Floor Covering Manufacturing
Principal Product Rubber Flooring
Sales $ 12,000,000
# of Employees 80
Plant Area (Sq.Ft.) 105,000
Annual Production 8,500,000 Pounds
Production Hrs. Annual 2,500
Location (State) OH
Yearly Energy Cost $ 1,122,121

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,034,918 kWh $ 455,652 $ 0.113 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 65,146 MMBtu $ 666,469 $ 10.23 /MMBtu

TOTAL ENERGY

 106,504 MMBtu $ 1,122,121 $ 10.54 /MMBtu

Water Disposal

 24,678 Gal $ 25,379 $ 1 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,088,092 kWh
514,358 kWh		 $ 79,962
$ 19,064		 17.55 %
4.18 %		 $ 0.113 /kWh

- Electricity Fees

 - $ 11,737
$ 11,737		 0.00 %
0.00 %		 -

Natural Gas

 27,839 MMBtu
25,687 MMBtu		 $ 284,789
$ 262,774		 42.73 %
39.43 %		 $ 10.23 /MMBtu

TOTAL ENERGY

 38,992 MMBtu
30,959 MMBtu		 $ 376,488
$ 293,575		 33.55 %
26.16 %		 $ 10.54 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 1 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ESTABLISH BURNER MAINTENANCE SCHEDULE FOR BOILERS 2.1231 I $ 20,000 $ 180,324 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 17,627 MMBtu $ 180,324 $ 10.23 /MMBtu

TOTAL ENERGY

 17,627 MMBtu $ 180,324 -
02 view
details		 SHUT OFF STEAM TRAPS ON SUPER HEATED STEAM LINES WHEN NOT IN USE 2.2114 I $ 0 $ 66,274 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,772 MMBtu $ 69,274 $ 10.23 /MMBtu

TOTAL ENERGY

 6,772 MMBtu $ 69,274 -

Personnel Changes

 - $ -3,000 -

TOTAL PRODUCTON

 - $ -3,000 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 28,000 $ 43,743 0.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 298,771 kWh $ 33,462 $ 0.113 /kWh

Natural Gas

 1,005 MMBtu $ 10,281 $ 10.23 /MMBtu

TOTAL ENERGY

 4,067 MMBtu $ 43,743 -
04 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 I $ 0 $ 12,848 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 458,858 kWh $ 12,848 $ 0.113 /kWh

TOTAL ENERGY

 4,703 MMBtu $ 12,848 -
05 view
details		 PAY BILLS ON TIME TO AVOID LATE FEES 4.8210 I $ 0 $ 11,737 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 11,737 -

TOTAL ENERGY

 0 MMBtu $ 11,737 -
06 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 2,358 $ 11,734 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,147 MMBtu $ 11,734 $ 10.23 /MMBtu

TOTAL ENERGY

 1,147 MMBtu $ 11,734 -
07 view
details		 USE HEAT FROM BOILER BLOWDOWN TO PREHEAT BOILER FEED WATER 2.1243 I $ 336 $ 11,202 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,095 MMBtu $ 11,202 $ 10.23 /MMBtu

TOTAL ENERGY

 1,095 MMBtu $ 11,202 -
08 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 15,000 $ 9,772 1.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 87,250 kWh $ 9,772 $ 0.113 /kWh

TOTAL ENERGY

 894 MMBtu $ 9,772 -
09 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 15,000 $ 7,364 2.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 65,750 kWh $ 7,364 $ 0.113 /kWh

TOTAL ENERGY

 674 MMBtu $ 7,364 -
10 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 2,164 $ 4,648 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 41,500 kWh $ 4,648 $ 0.113 /kWh

TOTAL ENERGY

 425 MMBtu $ 4,648 -
11 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 8,000 $ 2,940 2.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,250 kWh $ 2,940 $ 0.113 /kWh

TOTAL ENERGY

 269 MMBtu $ 2,940 -
12 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 12,625 $ 2,512 5.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,250 kWh $ 2,380 $ 0.113 /kWh

TOTAL ENERGY

 218 MMBtu $ 2,380 -

Ancillary Material Cost

 - $ 132 -

TOTAL PRODUCTON

 - $ 132 -
13 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 7,735 $ 2,250 3.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,480 kWh $ 2,294 $ 0.113 /kWh

TOTAL ENERGY

 210 MMBtu $ 2,294 -

Ancillary Material Cost

 - $ -44 -

TOTAL PRODUCTON

 - $ -44 -
14 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 6,668 $ 1,996 3.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,733 kWh $ 1,762 $ 0.113 /kWh

TOTAL ENERGY

 469 MMBtu $ 1,762 -

Ancillary Material Cost

 - $ 234 -

TOTAL PRODUCTON

 - $ 234 -
15 view
details		 CLOSE OFF UNNEEDED STEAM LINES 2.2153 I $ 1,100 $ 1,974 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 193 MMBtu $ 1,974 $ 10.23 /MMBtu

TOTAL ENERGY

 193 MMBtu $ 1,974 -
16 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 924 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,250 kWh $ 924 $ 0.113 /kWh

TOTAL ENERGY

 85 MMBtu $ 924 -
17 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 552 1.81
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,000 kWh $ 1,568 $ 0.113 /kWh

TOTAL ENERGY

 144 MMBtu $ 1,568 -

Personnel Changes

 - $ -816 -

Ancillary Material Cost

 - $ -200 -

TOTAL PRODUCTON

 - $ -1,016 -