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

Industrial Assessment Centers

Assessment #UD0839


Assessment Year 2011
SIC 2032
SIC Description Canned Specialties
NAICS 311422
NAICS Description Specialty Canning
Principal Product Packaged Food
Sales $ 175,000,000
# of Employees 365
Plant Area (Sq.Ft.) 182,000
Annual Production 125,000,000 Pieces
Production Hrs. Annual 6,000
Location (State) OH
Yearly Energy Cost $ 1,572,831

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 12,255,959 kWh $ 837,216 $ 0.068 /kWh

- Demand Charge

 24,611 kW $ 118,893 $ 4.83 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 96,888 MMBtu $ 616,722 $ 6.37 /MMBtu

TOTAL ENERGY

 222,513 MMBtu $ 1,572,831 $ 7.07 /MMBtu

Water Disposal

 213,915,284 Gal $ 991,312 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 719,317 kWh
593,608 kWh		 $ 44,700
$ 36,803		 5.34 %
4.40 %		 $ 0.068 /kWh

- Demand Charge

 736 kW
448 kW		 $ 3,231
$ 1,988		 2.72 %
1.67 %		 $ 4.83 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 19,044 MMBtu
5,209 MMBtu		 $ 121,613
$ 33,486		 19.72 %
5.43 %		 $ 6.37 /MMBtu

TOTAL ENERGY

 26,417 MMBtu
11,294 MMBtu		 $ 169,544
$ 72,277		 10.78 %
4.60 %		 $ 7.07 /MMBtu

Water Disposal

 8,212,292 Gal
8,212,292 Gal		 $ 38,098
$ 38,098		 3.84 %
3.84 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 5,668 $ 4,985 1.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 57,250 kWh $ 3,549 $ 0.068 /kWh

- Demand Charge

 100 kW $ 459 $ 4.83 /kW

TOTAL ENERGY

 587 MMBtu $ 4,008 -

Personnel Changes

 - $ 977 -

TOTAL PRODUCTON

 - $ 977 -
02 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 1,875 $ 1,620 1.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,810 kWh $ 1,517 $ 0.068 /kWh

TOTAL ENERGY

 234 MMBtu $ 1,517 -

Personnel Changes

 - $ 103 -

TOTAL PRODUCTON

 - $ 103 -
03 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 500 $ 58,395 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 435,664 kWh $ 27,011 $ 0.068 /kWh

- Demand Charge

 600 kW $ 2,632 $ 4.83 /kW

TOTAL ENERGY

 4,466 MMBtu $ 29,643 -

Personnel Changes

 - $ -300 -

Ancillary Material Cost

 - $ 29,052 -

TOTAL PRODUCTON

 - $ 28,752 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 0 $ 20,472 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 214,848 kWh $ 13,321 $ 0.068 /kWh

TOTAL ENERGY

 2,202 MMBtu $ 13,321 -

Personnel Changes

 - $ -625 -

Ancillary Material Cost

 - $ 7,776 -

TOTAL PRODUCTON

 - $ 7,151 -
05 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 5,000 $ 7,623 0.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 102,899 kWh $ 6,380 $ 0.068 /kWh

- Demand Charge

 288 kW $ 1,243 $ 4.83 /kW

TOTAL ENERGY

 1,055 MMBtu $ 7,623 -
06 view
details		 PREHEAT BOILER MAKEUP WATER WITH WASTE PROCESS HEAT 2.2441 N $ 90,000 $ 80,401 1.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,380 MMBtu $ 27,901 $ 6.37 /MMBtu

TOTAL ENERGY

 4,380 MMBtu $ 27,901 -

Administrative Changes

 - $ 52,500 -

TOTAL PRODUCTON

 - $ 52,500 -
07 view
details		 USE STEAM CONDENSATE FOR HOT WATER SUPPLY (NON-POTABLE) 2.2128 N $ 59,764 $ 29,882 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,489 MMBtu $ 28,593 $ 6.37 /MMBtu

TOTAL ENERGY

 4,489 MMBtu $ 28,593 -

Water Consumption

 - $ 1,289 -

TOTAL PRODUCTON

 - $ 1,289 -
08 view
details		 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES 2.1221 N $ 90,000 $ 80,401 1.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,380 MMBtu $ 27,901 $ 6.37 /MMBtu

TOTAL ENERGY

 4,380 MMBtu $ 27,901 -

Ancillary Material Cost

 - $ 52,500 -

TOTAL PRODUCTON

 - $ 52,500 -
09 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 3,000 $ 14,418 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,264 MMBtu $ 14,418 $ 6.37 /MMBtu

TOTAL ENERGY

 2,264 MMBtu $ 14,418 -
10 view
details		 OPERATE BOILERS ON HIGH FIRE SETTING 2.1212 I $ 23,620 $ 11,810 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,854 MMBtu $ 11,810 $ 6.37 /MMBtu

TOTAL ENERGY

 1,854 MMBtu $ 11,810 -
11 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 I $ 2,100 $ 5,425 0.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 828 MMBtu $ 5,271 $ 6.37 /MMBtu

TOTAL ENERGY

 828 MMBtu $ 5,271 -

Water Consumption

 - $ 154 -

TOTAL PRODUCTON

 - $ 154 -
12 view
details		 INSTALL / REPAIR INSULATION ON CONDENSATE LINES 2.2122 I $ 993 $ 1,987 0.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 263 MMBtu $ 1,987 $ 6.37 /MMBtu

TOTAL ENERGY

 263 MMBtu $ 1,987 -
13 view
details		 USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION 3.4111 I $ 75,000 $ 48,911 1.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -114,154 kWh $ -7,078 $ 0.068 /kWh

- Demand Charge

 -252 kW $ -1,103 $ 4.83 /kW

TOTAL ENERGY

 -1,170 MMBtu $ -8,181 -

Water Disposal

 8,212,292 Gal $ 38,098 $ 0 /Gal

TOTAL WASTE

 - $ 38,098 -

Water Consumption

 - $ 18,994 -

TOTAL PRODUCTON

 - $ 18,994 -
14 view
details		 INSTALL FOSSIL FUEL MAKE-UP AIR UNIT 2.7235 N $ 25 $ 3,732 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 586 MMBtu $ 3,732 $ 6.37 /MMBtu

TOTAL ENERGY

 586 MMBtu $ 3,732 -