U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #UD0853


Assessment Year 2012
SIC 3069
SIC Description Fabricated Rubber Products, Nec
NAICS 326299
NAICS Description All Other Rubber Product Manufacturing
Principal Product Rubber Inserts
Sales $ 35,200,000
# of Employees 229
Plant Area (Sq.Ft.) 64,500
Annual Production 117,942,795 Pieces
Production Hrs. Annual 6,000
Location (State) IN
Yearly Energy Cost $ 794,706

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,762,578 kWh $ 317,994 $ 0.033 /kWh

- Demand Charge

 19,284 kW $ 371,223 $ 19.25 /kW

- Electricity Fees

 - $ 2,078 -

Natural Gas

 9,329 MMBtu $ 103,411 $ 11.08 /MMBtu

TOTAL ENERGY

 109,396 MMBtu $ 794,706 $ 7.26 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,184,227 kWh
0 kWh		 $ 39,200
$ 0		 12.33 %
0.00 %		 $ 0.033 /kWh

- Demand Charge

 1,199 kW
0 kW		 $ 23,461
$ 0		 6.32 %
0.00 %		 $ 19.25 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 276 MMBtu
0 MMBtu		 $ 3,114
$ 0		 3.01 %
0.00 %		 $ 11.08 /MMBtu

TOTAL ENERGY

 12,414 MMBtu
0 MMBtu		 $ 65,775
$ 0		 8.28 %
0.00 %		 $ 7.26 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 28,511 $ 30,419 0.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 534,865 kWh $ 17,752 $ 0.033 /kWh

- Demand Charge

 648 kW $ 12,667 $ 19.25 /kW

TOTAL ENERGY

 5,482 MMBtu $ 30,419 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 3,815 $ 2,997 1.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 49,327 kWh $ 1,637 $ 0.033 /kWh

- Demand Charge

 72 kW $ 1,360 $ 19.25 /kW

TOTAL ENERGY

 506 MMBtu $ 2,997 -
03 view
details		 REDUCE WATER USE WITH COUNTER CURRENT RINSING 3.1222 N $ 600 $ 15,738 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Consumption

 - $ 15,738 -

TOTAL PRODUCTON

 - $ 15,738 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 5,500 $ 4,192 1.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,894 kWh $ 2,320 $ 0.033 /kWh

- Demand Charge

 96 kW $ 1,872 $ 19.25 /kW

TOTAL ENERGY

 716 MMBtu $ 4,192 -
05 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 6,000 $ 6,272 0.96
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 88,608 kWh $ 2,941 $ 0.033 /kWh

- Demand Charge

 168 kW $ 3,331 $ 19.25 /kW

TOTAL ENERGY

 908 MMBtu $ 6,272 -
06 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 N $ 7,000 $ 4,059 1.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 122,304 kWh $ 4,059 $ 0.033 /kWh

TOTAL ENERGY

 1,254 MMBtu $ 4,059 -
07 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 1,000 $ 3,012 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -1,679 kWh $ -56 $ 0.033 /kWh

- Demand Charge

 -3 kW $ -46 $ 19.25 /kW

Natural Gas

 276 MMBtu $ 3,114 $ 11.08 /MMBtu

TOTAL ENERGY

 259 MMBtu $ 3,012 -
08 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 1,000 $ 2,506 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,396 kWh $ 1,175 $ 0.033 /kWh

- Demand Charge

 72 kW $ 1,331 $ 19.25 /kW

TOTAL ENERGY

 363 MMBtu $ 2,506 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 2,000 $ 974 2.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,247 kWh $ 435 $ 0.033 /kWh

- Demand Charge

 23 kW $ 539 $ 19.25 /kW

TOTAL ENERGY

 167 MMBtu $ 974 -
10 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 1,300 $ 402 3.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,505 kWh $ 83 $ 0.033 /kWh

- Demand Charge

 14 kW $ 319 $ 19.25 /kW

TOTAL ENERGY

 26 MMBtu $ 402 -
11 view
details		 COVER OPEN TANKS WITH FLOATING INSULATION 2.2513 N $ 200 $ 4,120 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 53,574 kWh $ 1,778 $ 0.033 /kWh

- Demand Charge

 108 kW $ 2,088 $ 19.25 /kW

TOTAL ENERGY

 549 MMBtu $ 3,866 -

Water Consumption

 - $ 254 -

TOTAL PRODUCTON

 - $ 254 -
12 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 N $ 9,000 $ 7,076 1.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 213,186 kWh $ 7,076 $ 0.033 /kWh

TOTAL ENERGY

 2,185 MMBtu $ 7,076 -