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

Industrial Assessment Centers

Assessment #UD0809


Assessment Year 2009
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Custom profile extrustions for decking and railing
Sales $ 45,000,000
# of Employees 60
Plant Area (Sq.Ft.) 120,000
Annual Production 27,000,000 Pounds
Production Hrs. Annual 8,400
Location (State) OH
Yearly Energy Cost $ 551,858

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 8,742,150 kWh $ 308,947 $ 0.035 /kWh

- Demand Charge

 1,411 kW $ 211,385 $ 149.81 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 3,046 MMBtu $ 31,526 $ 10.35 /MMBtu

TOTAL ENERGY

 92,653 MMBtu $ 551,858 $ 5.96 /MMBtu

Water Disposal

 4,587 Gal $ 16,513 $ 4 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,493,271 kWh
993,123 kWh		 $ 51,160
$ 34,738		 16.56 %
11.24 %		 $ 0.035 /kWh

- Demand Charge

 133 kW
75 kW		 $ 17,104
$ 8,090		 8.09 %
3.83 %		 $ 149.81 /kW

- Electricity Fees

 - $ 15,628
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 884 MMBtu
866 MMBtu		 $ 9,142
$ 8,961		 29.00 %
28.42 %		 $ 10.35 /MMBtu

TOTAL ENERGY

 16,188 MMBtu
11,045 MMBtu		 $ 93,034
$ 51,789		 16.86 %
9.38 %		 $ 5.96 /MMBtu

Water Disposal

 336 Gal
0 Gal		 $ 1,858
$ 0		 11.25 %
0.00 %		 $ 4 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RECYCLE AIR FOR HEATING, VENTILATION AND AIR CONDITIONING 2.7313 I $ 5,640 $ 22,565 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 283,500 kWh $ 9,923 $ 0.035 /kWh

- Demand Charge

 34 kW $ 3,681 $ 149.81 /kW

Natural Gas

 866 MMBtu $ 8,961 $ 10.35 /MMBtu

TOTAL ENERGY

 3,772 MMBtu $ 22,565 -
02 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 120,000 $ 20,495 5.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 260,400 kWh $ 9,114 $ 0.035 /kWh

- Demand Charge

 31 kW $ 3,381 $ 149.81 /kW

TOTAL ENERGY

 2,669 MMBtu $ 12,495 -

Ancillary Material Cost

 - $ 8,000 -

TOTAL PRODUCTON

 - $ 8,000 -
03 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 20,000 $ 15,628 1.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 15,628 -

TOTAL ENERGY

 0 MMBtu $ 15,628 -
04 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 8,423 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 240,660 kWh $ 8,423 $ 0.035 /kWh

TOTAL ENERGY

 2,467 MMBtu $ 8,423 -
05 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 324 $ 6,288 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 131,040 kWh $ 4,586 $ 0.035 /kWh

- Demand Charge

 16 kW $ 1,702 $ 149.81 /kW

TOTAL ENERGY

 1,343 MMBtu $ 6,288 -
06 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 1,000 $ 5,845 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 121,800 kWh $ 4,263 $ 0.035 /kWh

- Demand Charge

 15 kW $ 1,582 $ 149.81 /kW

TOTAL ENERGY

 1,248 MMBtu $ 5,845 -
07 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 0 $ 4,812 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 100,296 kWh $ 1,302 $ 0.035 /kWh

- Demand Charge

 12 kW $ 3,510 $ 149.81 /kW

TOTAL ENERGY

 1,028 MMBtu $ 4,812 -
08 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 I $ 23,400 $ 4,116 5.69
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 117,600 kWh $ 4,116 $ 0.035 /kWh

TOTAL ENERGY

 1,205 MMBtu $ 4,116 -
09 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 1,440 $ 2,822 0.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,800 kWh $ 2,058 $ 0.035 /kWh

- Demand Charge

 7 kW $ 764 $ 149.81 /kW

TOTAL ENERGY

 603 MMBtu $ 2,822 -
10 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 1,048 $ 2,765 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 57,666 kWh $ 2,018 $ 0.035 /kWh

- Demand Charge

 7 kW $ 749 $ 149.81 /kW

TOTAL ENERGY

 591 MMBtu $ 2,767 -

Ancillary Material Cost

 - $ -2 -

TOTAL PRODUCTON

 - $ -2 -
11 view
details		 ELIMINATE LEAKS IN WATER LINES AND VALVES 3.4154 N $ 480 $ 1,858 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 336 Gal $ 1,858 $ 4 /Gal

TOTAL WASTE

 - $ 1,858 -
12 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 8,270 $ 1,411 5.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,400 kWh $ 382 $ 0.035 /kWh

- Demand Charge

 4 kW $ 1,029 $ 149.81 /kW

TOTAL ENERGY

 301 MMBtu $ 1,411 -
13 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 1,703 $ 1,348 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,470 kWh $ 730 $ 0.035 /kWh

- Demand Charge

 3 kW $ 279 $ 149.81 /kW

TOTAL ENERGY

 220 MMBtu $ 1,009 -

Ancillary Material Cost

 - $ 339 -

TOTAL PRODUCTON

 - $ 339 -
14 view
details		 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 2.7121 N $ 5,467 $ 2,678 2.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,884 kWh $ 2,678 $ 0.035 /kWh

TOTAL ENERGY

 265 MMBtu $ 2,678 -
15 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 685 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,280 kWh $ 500 $ 0.035 /kWh

- Demand Charge

 2 kW $ 185 $ 149.81 /kW

TOTAL ENERGY

 146 MMBtu $ 685 -
16 view
details		 DISCONNECT BALLASTS 2.7122 N $ 0 $ 532 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,088 kWh $ 388 $ 0.035 /kWh

- Demand Charge

 1 kW $ 144 $ 149.81 /kW

TOTAL ENERGY

 114 MMBtu $ 532 -
17 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 414 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,827 kWh $ 414 $ 0.035 /kWh

TOTAL ENERGY

 121 MMBtu $ 414 -
18 view
details		 CHILL WATER TO THE HIGHEST TEMPERATURE POSSIBLE 2.2625 N $ 0 $ 363 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,560 kWh $ 265 $ 0.035 /kWh

- Demand Charge

 1 kW $ 98 $ 149.81 /kW

TOTAL ENERGY

 77 MMBtu $ 363 -
19 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 500 $ 181 2.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 18 MMBtu $ 181 $ 10.35 /MMBtu

TOTAL ENERGY

 18 MMBtu $ 181 -