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

Industrial Assessment Centers

Assessment #UD0838


Assessment Year 2011
SIC 2273
SIC Description Carpets And Rugs
NAICS 314110
NAICS Description Carpet and Rug Mills
Principal Product Automotive Textile Acoustical Systems
Sales $ 48,600,000
# of Employees 275
Plant Area (Sq.Ft.) 192,000
Annual Production 1,200,000 Pounds
Production Hrs. Annual 6,000
Location (State) OH
Yearly Energy Cost $ 942,731

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,831,200 kWh $ 531,604 $ 0.049 /kWh

- Demand Charge

 28,680 kW $ 384,025 $ 13.39 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 2,485 MMBtu $ 27,102 $ 10.91 /MMBtu

TOTAL ENERGY

 113,506 MMBtu $ 942,731 $ 8.31 /MMBtu

Water Disposal

 1,391,280 Gal $ 9,637 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,339,521 kWh
246,361 kWh		 $ 57,599
$ 10,594		 10.83 %
1.99 %		 $ 0.049 /kWh

- Demand Charge

 3,383 kW
452 kW		 $ 46,743
$ 6,598		 12.17 %
1.72 %		 $ 13.39 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,364 MMBtu
527 MMBtu		 $ 25,775
$ 5,749		 95.10 %
21.21 %		 $ 10.91 /MMBtu

TOTAL ENERGY

 16,094 MMBtu
3,052 MMBtu		 $ 130,117
$ 22,941		 13.80 %
2.43 %		 $ 8.31 /MMBtu

Water Disposal

 703,120 Gal
0 Gal		 $ 4,766
$ 0		 49.46 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION 3.4111 N $ 15,000 $ 9,635 1.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 703,120 Gal $ 4,766 $ 0 /Gal

TOTAL WASTE

 - $ 4,766 -

Water Consumption

 - $ 4,869 -

TOTAL PRODUCTON

 - $ 4,869 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 55,000 $ 47,095 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 582,000 kWh $ 25,026 $ 0.049 /kWh

- Demand Charge

 1,300 kW $ 18,703 $ 13.39 /kW

TOTAL ENERGY

 5,966 MMBtu $ 43,729 -

Personnel Changes

 - $ 3,366 -

TOTAL PRODUCTON

 - $ 3,366 -
03 view
details		 UPGRADE OBSOLETE EQUIPMENT 2.4321 I $ 20,000 $ 14,654 1.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 210,000 kWh $ 9,030 $ 0.049 /kWh

- Demand Charge

 380 kW $ 5,624 $ 13.39 /kW

TOTAL ENERGY

 2,153 MMBtu $ 14,654 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 2,238 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 36,361 kWh $ 1,564 $ 0.049 /kWh

- Demand Charge

 72 kW $ 974 $ 13.39 /kW

TOTAL ENERGY

 373 MMBtu $ 2,538 -

Personnel Changes

 - $ -300 -

TOTAL PRODUCTON

 - $ -300 -
05 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 7,000 $ 2,034 3.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,150 kWh $ 1,253 $ 0.049 /kWh

- Demand Charge

 60 kW $ 781 $ 13.39 /kW

TOTAL ENERGY

 299 MMBtu $ 2,034 -
06 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 124,541 $ 24,370 5.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 195,375 kWh $ 8,401 $ 0.049 /kWh

- Demand Charge

 1,176 kW $ 15,969 $ 13.39 /kW

TOTAL ENERGY

 2,003 MMBtu $ 24,370 -
07 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 100,000 $ 17,828 5.61
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 298,400 kWh $ 12,831 $ 0.049 /kWh

- Demand Charge

 372 kW $ 4,997 $ 13.39 /kW

TOTAL ENERGY

 3,059 MMBtu $ 17,828 -
08 view
details		 IMPROVE AIR CIRCULATION WITH DESTRATIFICATION FANS / OTHER METHODS 2.7243 N $ 78,000 $ 11,630 6.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -11,765 kWh $ -506 $ 0.049 /kWh

- Demand Charge

 23 kW $ -305 $ 13.39 /kW

Natural Gas

 1,141 MMBtu $ 12,441 $ 10.91 /MMBtu

TOTAL ENERGY

 1,020 MMBtu $ 11,630 -
09 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 15,000 $ 7,585 1.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 696 MMBtu $ 7,585 $ 10.91 /MMBtu

TOTAL ENERGY

 696 MMBtu $ 7,585 -
10 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 125 $ 5,749 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 527 MMBtu $ 5,749 $ 10.91 /MMBtu

TOTAL ENERGY

 527 MMBtu $ 5,749 -