Industrial Assessment Centers

Assessment #UD0807

Assessment Year	2009
SIC	3082
SIC Description	Unsupported Plastics Profile Shapes
NAICS	326121
NAICS Description	Unlaminated Plastics Profile Shape Manufacturing
Principal Product	Custom profile extrusions for windows, doors and office furniture
Sales	$ 30,000,000
# of Employees	200
Plant Area (Sq.Ft.)	250,000
Annual Production	17,000,000 Pounds
Production Hrs. Annual	8,400
Location (State)	OH
Yearly Energy Cost	$ 994,707

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	17,913,059 kWh	$ 954,373	$ 0.053 /kWh
- Demand Charge	3,316 kW	$ 0	$ 0.00 /kW
- Electricity Fees	-	$ 0	-
Natural Gas	4,139 MMBtu	$ 40,334	$ 9.74 /MMBtu
TOTAL ENERGY	187,748 MMBtu	$ 994,707	$ 5.30 /MMBtu
Water Disposal	8,258,668 Gal	$ 38,794	$ 0 /Gal

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	3,676,953 kWh 968,105 kWh	$ 132,449 $ 34,860	13.88 % 3.65 %	$ 0.053 /kWh
- Demand Charge	430 kW 115 kW	$ 46,955 $ 12,574	0.00 % 0.00 %	$ 0.00 /kW
- Electricity Fees	-	$ 78,142 $ 0	0.00 % 0.00 %	-
Natural Gas	0 MMBtu 0 MMBtu	$ 0 $ 0	0.00 % 0.00 %	$ 9.74 /MMBtu
TOTAL ENERGY	37,689 MMBtu 9,923 MMBtu	$ 257,546 $ 47,434	25.89 % 4.77 %	$ 5.30 /MMBtu
Water Disposal	1,638,120 Gal 0 Gal	$ 8,518 $ 0	21.96 % 0.00 %	$ 0 /Gal

Recommendations

AR #

Description

ARC Code

Status

Cost

Savings

Payback
(Years)

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details

REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED

2.4231

$ 2,000

$ 11,275

0.18

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	230,160 kWh	$ 8,286	$ 0.053 /kWh
- Demand Charge	27 kW	$ 2,989	$ 0.00 /kW
TOTAL ENERGY	2,359 MMBtu	$ 11,275	-

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details

ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES

2.4236

$ 1,000

$ 4,575

0.22

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	172,000 kWh	$ 6,199	$ 0.053 /kWh
- Demand Charge	21 kW	$ 2,236	$ 0.00 /kW
TOTAL ENERGY	1,763 MMBtu	$ 8,435	-
Personnel Changes	-	$ -3,360	-
Ancillary Material Cost	-	$ -500	-
TOTAL PRODUCTON	-	$ -3,860	-

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details

ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING

2.4232

$ 15,550

$ 65,548

0.24

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	1,338,120 kWh	$ 48,172	$ 0.053 /kWh
- Demand Charge	159 kW	$ 17,376	$ 0.00 /kW
TOTAL ENERGY	13,716 MMBtu	$ 65,548	-

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details

INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS

2.4221

$ 1,000

$ 1,604

0.62

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	30,760 kWh	$ 1,179	$ 0.053 /kWh
- Demand Charge	4 kW	$ 425	$ 0.00 /kW
TOTAL ENERGY	315 MMBtu	$ 1,604	-

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details

USE / PURCHASE OPTIMUM SIZED COMPRESSOR

2.4226

$ 52,550

$ 12,056

4.36

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	246,120 kWh	$ 8,860	$ 0.053 /kWh
- Demand Charge	29 kW	$ 3,196	$ 0.00 /kW
TOTAL ENERGY	2,523 MMBtu	$ 12,056	-

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details

UPGRADE CONTROLS ON COMPRESSORS

2.4224

$ 7,000

$ 1,564

4.48

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	31,920 kWh	$ 1,149	$ 0.053 /kWh
- Demand Charge	4 kW	$ 415	$ 0.00 /kW
TOTAL ENERGY	327 MMBtu	$ 1,564	-

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details

OPTIMIZE PLANT POWER FACTOR

2.3212

$ 100,000

$ 78,142

1.28

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
- Electricity Fees	-	$ 78,142	-
TOTAL ENERGY	0 MMBtu	$ 78,142	-

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details

USE COOLING TOWER WATER INSTEAD OF REFRIGERATION

2.2612

$ 0

$ 22,644

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	628,992 kWh	$ 22,644	$ 0.053 /kWh
TOTAL ENERGY	6,447 MMBtu	$ 22,644	-

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details

UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS

2.7142

$ 8,602

$ 18,425

0.47

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	376,135 kWh	$ 13,541	$ 0.053 /kWh
- Demand Charge	45 kW	$ 4,884	$ 0.00 /kW
TOTAL ENERGY	3,855 MMBtu	$ 18,425	-

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details

SHIFT FROM DAYTIME TO NIGHTTIME OPERATION

2.3134

$ 0

$ 10,853

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
- Demand Charge	99 kW	$ 10,853	$ 0.00 /kW
TOTAL ENERGY	0 MMBtu	$ 10,853	-

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details

USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS

2.4141

$ 23,924

$ 9,719

2.46

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	269,976 kWh	$ 9,719	$ 0.053 /kWh
TOTAL ENERGY	2,767 MMBtu	$ 9,719	-

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details

UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS

2.7142

$ 4,614

$ 9,249

0.50

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	138,432 kWh	$ 4,984	$ 0.053 /kWh
- Demand Charge	16 kW	$ 1,798	$ 0.00 /kW
TOTAL ENERGY	1,419 MMBtu	$ 6,782	-
Personnel Changes	-	$ 2,467	-
TOTAL PRODUCTON	-	$ 2,467	-

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details

MINIMIZE WATER USAGE

3.4151

$ 5,000

$ 5,548

0.90

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Disposal	1,021,020 Gal	$ 5,548	$ 0 /Gal
TOTAL WASTE	-	$ 5,548	-

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details

CHILL WATER TO THE HIGHEST TEMPERATURE POSSIBLE

2.2625

$ 0

$ 4,896

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	99,960 kWh	$ 3,598	$ 0.053 /kWh
- Demand Charge	12 kW	$ 1,298	$ 0.00 /kW
TOTAL ENERGY	1,025 MMBtu	$ 4,896	-

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details

INSULATE BARE EQUIPMENT

2.2511

$ 2,700

$ 3,086

0.87

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	63,000 kWh	$ 2,268	$ 0.053 /kWh
- Demand Charge	8 kW	$ 818	$ 0.00 /kW
TOTAL ENERGY	646 MMBtu	$ 3,086	-

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details

METER RECYCLED WATER (TO REDUCE SEWER CHARGES)

3.4116

$ 2,000

$ 2,970

0.67

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Disposal	617,100 Gal	$ 2,970	$ 0 /Gal
TOTAL WASTE	-	$ 2,970	-

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details

UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS

2.7142

$ 2,533

$ 2,776

0.91

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	51,378 kWh	$ 1,850	$ 0.053 /kWh
- Demand Charge	6 kW	$ 667	$ 0.00 /kW
TOTAL ENERGY	527 MMBtu	$ 2,517	-
Ancillary Material Cost	-	$ 259	-
TOTAL PRODUCTON	-	$ 259	-