Industrial Assessment Centers

Assessment #UD0852

Assessment Year	2012
SIC	3085
SIC Description	Plastics Bottles
NAICS	326160
NAICS Description	Plastics Bottle Manufacturing
Principal Product	Plastic Bottles
Sales	$ 100,000,000
# of Employees	170
Plant Area (Sq.Ft.)	255,105
Annual Production	40,141,300 Pounds
Production Hrs. Annual	6,000
Location (State)	IN
Yearly Energy Cost	$ 2,367,376

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	31,601,500 kWh	$ 1,396,729	$ 0.044 /kWh
- Demand Charge	67,392 kW	$ 948,205	$ 14.07 /kW
- Electricity Fees	-	$ 0	-
Natural Gas	2,859 MMBtu	$ 22,442	$ 7.85 /MMBtu
TOTAL ENERGY	326,778 MMBtu	$ 2,367,376	$ 7.24 /MMBtu

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	4,925,077 kWh 1,086,172 kWh	$ 207,356 $ 45,729	14.85 % 3.27 %	$ 0.044 /kWh
- Demand Charge	8,816 kW 1,292 kW	$ 124,228 $ 18,159	13.10 % 1.92 %	$ 14.07 /kW
- Electricity Fees	-	$ 0 $ 0	0.00 % 0.00 %	-
Natural Gas	0 MMBtu 0 MMBtu	$ 0 $ 0	0.00 % 0.00 %	$ 7.85 /MMBtu
TOTAL ENERGY	50,483 MMBtu 11,133 MMBtu	$ 331,584 $ 63,888	14.01 % 2.70 %	$ 7.24 /MMBtu

Recommendations

AR #

Description

ARC Code

Status

Cost

Savings

Payback
(Years)

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details

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

2.4141

$ 342,000

$ 156,438

2.19

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	2,227,000 kWh	$ 93,765	$ 0.044 /kWh
- Demand Charge	4,452 kW	$ 62,673	$ 14.07 /kW
TOTAL ENERGY	22,827 MMBtu	$ 156,438	-

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details

REDUCE TEMPERATURE OF PROCESS EQUIPMENT WHEN ON STANDBY

2.6241

$ 8,250

$ 13,731

0.60

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	195,496 kWh	$ 8,230	$ 0.044 /kWh
- Demand Charge	384 kW	$ 5,501	$ 14.07 /kW
TOTAL ENERGY	2,004 MMBtu	$ 13,731	-

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details

UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS

2.4111

$ 0

$ 1,349

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	19,205 kWh	$ 809	$ 0.044 /kWh
- Demand Charge	36 kW	$ 540	$ 14.07 /kW
TOTAL ENERGY	197 MMBtu	$ 1,349	-

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details

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

2.4141

$ 6,000

$ 41,934

0.14

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	746,548 kWh	$ 31,430	$ 0.044 /kWh
- Demand Charge	744 kW	$ 10,504	$ 14.07 /kW
TOTAL ENERGY	7,652 MMBtu	$ 41,934	-

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details

ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES

2.4236

$ 1,000

$ 4,072

0.25

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	75,055 kWh	$ 3,160	$ 0.044 /kWh
- Demand Charge	156 kW	$ 2,112	$ 14.07 /kW
TOTAL ENERGY	769 MMBtu	$ 5,272	-
Personnel Changes	-	$ -1,200	-
TOTAL PRODUCTON	-	$ -1,200	-

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details

INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS

2.4221

$ 5,000

$ 2,716

1.84

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	38,656 kWh	$ 1,628	$ 0.044 /kWh
- Demand Charge	72 kW	$ 1,088	$ 14.07 /kW
TOTAL ENERGY	396 MMBtu	$ 2,716	-

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details

INSULATE BARE EQUIPMENT

2.2511

$ 190,000

$ 94,327

2.01

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	1,308,000 kWh	$ 55,067	$ 0.044 /kWh
- Demand Charge	2,616 kW	$ 36,807	$ 14.07 /kW
TOTAL ENERGY	13,407 MMBtu	$ 91,874	-
Administrative Changes	-	$ 2,453	-
TOTAL PRODUCTON	-	$ 2,453	-

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details

USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING

2.2614

$ 50,000

$ 15,333

3.26

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	245,364 kWh	$ 10,330	$ 0.044 /kWh
- Demand Charge	356 kW	$ 5,003	$ 14.07 /kW
TOTAL ENERGY	2,515 MMBtu	$ 15,333	-

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details

USE SOLAR HEAT TO MAKE ELECTRICTY

2.9114

$ 106,738

$ 27,604

3.87

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	69,753 kWh	$ 2,937	$ 0.044 /kWh
TOTAL ENERGY	715 MMBtu	$ 2,937	-
Administrative Changes	-	$ 24,667	-
TOTAL PRODUCTON	-	$ 24,667	-