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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #UD0863


Assessment Year 2012
SIC 3061
SIC Description Mechanical Rubber Goods
NAICS 326291
NAICS Description Rubber Product Manufacturing for Mechanical Use
Principal Product rubber vibration isolation
Sales $ 174,000,000
# of Employees 450
Plant Area (Sq.Ft.) 205,000
Annual Production 100,000,000 Pieces
Production Hrs. Annual 8,400
Location (State) OH
Yearly Energy Cost $ 1,667,163

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 17,246,230 kWh $ 1,135,919 $ 0.066 /kWh

- Demand Charge

 36,069 kW $ 194,051 $ 5.38 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 68,728 MMBtu $ 337,193 $ 4.91 /MMBtu

TOTAL ENERGY

 245,504 MMBtu $ 1,667,163 $ 6.79 /MMBtu

Water Disposal

 9,457,621 Gal $ 89,842 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,071,034 kWh
458,398 kWh		 $ 68,170
$ 29,176		 6.00 %
2.57 %		 $ 0.066 /kWh

- Demand Charge

 1,559 kW
685 kW		 $ 8,370
$ 3,660		 4.31 %
1.89 %		 $ 5.38 /kW

- Electricity Fees

 - $ 4,421
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 19,277 MMBtu
13,609 MMBtu		 $ 94,658
$ 66,824		 28.07 %
19.82 %		 $ 4.91 /MMBtu

TOTAL ENERGY

 30,255 MMBtu
18,308 MMBtu		 $ 175,619
$ 99,660		 10.53 %
5.98 %		 $ 6.79 /MMBtu

Water Disposal

 2,480,540 Gal
0 Gal		 $ 23,578
$ 0		 26.24 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 TREAT AND REUSE RINSE WATERS 3.4113 N $ 1,000 $ 23,578 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 2,480,540 Gal $ 23,578 $ 0 /Gal

TOTAL WASTE

 - $ 23,578 -
02 view
details		 COMBINE UTILITY METERS 2.8112 N $ 8,842 $ 4,421 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 4,421 -

TOTAL ENERGY

 0 MMBtu $ 4,421 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 16,259 $ 7,407 2.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 98,784 kWh $ 6,288 $ 0.066 /kWh

- Demand Charge

 168 kW $ 886 $ 5.38 /kW

TOTAL ENERGY

 1,013 MMBtu $ 7,174 -

Administrative Changes

 - $ 233 -

TOTAL PRODUCTON

 - $ 233 -
04 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 557 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,682 kWh $ 488 $ 0.066 /kWh

- Demand Charge

 12 kW $ 69 $ 5.38 /kW

TOTAL ENERGY

 79 MMBtu $ 557 -
05 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 N $ 8,000 $ 16,871 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 236,496 kWh $ 15,053 $ 0.066 /kWh

- Demand Charge

 336 kW $ 1,818 $ 5.38 /kW

TOTAL ENERGY

 2,424 MMBtu $ 16,871 -
06 view
details		 ELIMINATE PERMANENTLY THE USE OF COMPRESSED AIR 2.4233 N $ 9,900 $ 18,285 0.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 256,331 kWh $ 16,315 $ 0.066 /kWh

- Demand Charge

 366 kW $ 1,970 $ 5.38 /kW

TOTAL ENERGY

 2,627 MMBtu $ 18,285 -
07 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 0 $ 16,249 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 227,784 kWh $ 14,498 $ 0.066 /kWh

- Demand Charge

 325 kW $ 1,751 $ 5.38 /kW

TOTAL ENERGY

 2,335 MMBtu $ 16,249 -
08 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 2,000 $ 8,548 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 119,809 kWh $ 7,626 $ 0.066 /kWh

- Demand Charge

 172 kW $ 922 $ 5.38 /kW

TOTAL ENERGY

 1,228 MMBtu $ 8,548 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 8,856 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 124,148 kWh $ 7,902 $ 0.066 /kWh

- Demand Charge

 180 kW $ 954 $ 5.38 /kW

TOTAL ENERGY

 1,273 MMBtu $ 8,856 -
10 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 I $ 0 $ 13,284 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,705 MMBtu $ 13,284 $ 4.91 /MMBtu

TOTAL ENERGY

 2,705 MMBtu $ 13,284 -
11 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 I $ 2,600 $ 10,008 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,038 MMBtu $ 10,008 $ 4.91 /MMBtu

TOTAL ENERGY

 2,038 MMBtu $ 10,008 -
12 view
details		 REDUCE EXCESSIVE BOILER BLOWDOWN 2.1241 N $ 12,800 $ 4,619 2.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 940 MMBtu $ 4,619 $ 4.91 /MMBtu

TOTAL ENERGY

 940 MMBtu $ 4,619 -
13 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 0 $ 43,532 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 8,866 MMBtu $ 43,532 $ 4.91 /MMBtu

TOTAL ENERGY

 8,866 MMBtu $ 43,532 -
14 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 14,000 $ 23,215 0.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,728 MMBtu $ 23,215 $ 4.91 /MMBtu

TOTAL ENERGY

 4,728 MMBtu $ 23,215 -