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

Industrial Assessment Centers

Assessment #UD0851


Assessment Year 2012
SIC 2851
SIC Description Paints And Allied Products
NAICS 325510
NAICS Description Paint and Coating Manufacturing
Principal Product Paint
Sales $ 130,000,000
# of Employees 192
Plant Area (Sq.Ft.) 216,437
Annual Production 4,669 Thousand Gallons
Production Hrs. Annual 7,200
Location (State) OH
Yearly Energy Cost $ 844,522

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,503,400 kWh $ 346,659 $ 0.053 /kWh

- Demand Charge

 13,560 kW $ 203,500 $ 15.01 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 56,380 MMBtu $ 294,363 $ 5.22 /MMBtu

TOTAL ENERGY

 123,041 MMBtu $ 844,522 $ 6.86 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 767,831 kWh
0 kWh		 $ 45,034
$ 0		 12.99 %
0.00 %		 $ 0.053 /kWh

- Demand Charge

 1,030 kW
0 kW		 $ 17,250
$ 0		 8.48 %
0.00 %		 $ 15.01 /kW

- Electricity Fees

 - $ 7,623
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 23,695 MMBtu
0 MMBtu		 $ 123,688
$ 0		 42.02 %
0.00 %		 $ 5.22 /MMBtu

TOTAL ENERGY

 31,565 MMBtu
0 MMBtu		 $ 193,595
$ 0		 22.92 %
0.00 %		 $ 6.86 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE SOLAR HEAT TO MAKE ELECTRICTY 2.9114 N $ 42,695 $ 12,842 3.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,040 kWh $ 1,688 $ 0.053 /kWh

- Electricity Fees

 - $ 7,623 -

TOTAL ENERGY

 298 MMBtu $ 9,311 -

One-time Revenue or Avoided Cost

 - $ 3,531 -

TOTAL PRODUCTON

 - $ 3,531 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 4,016 $ 10,873 0.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 131,993 kWh $ 7,671 $ 0.053 /kWh

- Demand Charge

 168 kW $ 2,863 $ 15.01 /kW

TOTAL ENERGY

 1,353 MMBtu $ 10,534 -

Administrative Changes

 - $ 339 -

TOTAL PRODUCTON

 - $ 339 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 3,379 $ 8,335 0.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 94,913 kWh $ 5,516 $ 0.053 /kWh

- Demand Charge

 168 kW $ 2,863 $ 15.01 /kW

TOTAL ENERGY

 973 MMBtu $ 8,379 -

Personnel Changes

 - $ -44 -

TOTAL PRODUCTON

 - $ -44 -
04 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 3,660 $ 1,426 2.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,954 kWh $ 520 $ 0.053 /kWh

- Demand Charge

 48 kW $ 891 $ 15.01 /kW

TOTAL ENERGY

 92 MMBtu $ 1,411 -

Personnel Changes

 - $ 15 -

TOTAL PRODUCTON

 - $ 15 -
05 view
details		 REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE 2.4131 N $ 7,300 $ 7,266 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 100,288 kWh $ 5,829 $ 0.053 /kWh

- Demand Charge

 86 kW $ 1,437 $ 15.01 /kW

TOTAL ENERGY

 1,028 MMBtu $ 7,266 -
06 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 20,000 $ 15,652 1.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 195,672 kWh $ 11,372 $ 0.053 /kWh

- Demand Charge

 264 kW $ 4,280 $ 15.01 /kW

TOTAL ENERGY

 2,006 MMBtu $ 15,652 -
07 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 0 $ 8,543 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 99,608 kWh $ 5,789 $ 0.053 /kWh

- Demand Charge

 166 kW $ 2,754 $ 15.01 /kW

TOTAL ENERGY

 1,021 MMBtu $ 8,543 -
08 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 12,000 $ 5,739 2.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -1,380 kWh $ -80 $ 0.053 /kWh

- Demand Charge

 -3 kW $ -39 $ 15.01 /kW

Natural Gas

 1,122 MMBtu $ 5,858 $ 5.22 /MMBtu

TOTAL ENERGY

 1,108 MMBtu $ 5,739 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 5,000 $ 4,111 1.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,935 kWh $ 2,786 $ 0.053 /kWh

- Demand Charge

 84 kW $ 1,325 $ 15.01 /kW

TOTAL ENERGY

 491 MMBtu $ 4,111 -
10 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 1,000 $ 2,847 0.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 32,040 kWh $ 2,271 $ 0.053 /kWh

- Demand Charge

 48 kW $ 876 $ 15.01 /kW

TOTAL ENERGY

 328 MMBtu $ 3,147 -

Administrative Changes

 - $ -300 -

TOTAL PRODUCTON

 - $ -300 -
11 view
details		 USE FLUE GASES TO HEAT PROCESS OR SERVICE WATER 2.2425 N $ 32,000 $ 69,895 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 13,390 MMBtu $ 69,895 $ 5.22 /MMBtu

TOTAL ENERGY

 13,390 MMBtu $ 69,895 -
12 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 31,000 $ 27,723 1.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 5,311 MMBtu $ 27,723 $ 5.22 /MMBtu

TOTAL ENERGY

 5,311 MMBtu $ 27,723 -
13 view
details		 REDUCE EXCESSIVE BOILER BLOWDOWN 2.1241 N $ 5,000 $ 5,863 0.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,124 MMBtu $ 5,863 $ 5.22 /MMBtu

TOTAL ENERGY

 1,124 MMBtu $ 5,863 -
14 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 1,000 $ 5,300 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,015 MMBtu $ 5,300 $ 5.22 /MMBtu

TOTAL ENERGY

 1,015 MMBtu $ 5,300 -
15 view
details		 REDUCE VENTILATION AIR 2.7314 N $ 32,160 $ 10,721 3.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,768 kWh $ 1,672 $ 0.053 /kWh

Natural Gas

 1,733 MMBtu $ 9,049 $ 5.22 /MMBtu

TOTAL ENERGY

 2,028 MMBtu $ 10,721 -