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

Industrial Technologies Program

Assessment Year	2003
SIC	3087
SIC Description	Custom Compound Purchased Resins
NAICS	325211
NAICS Description	Plastics Material and Resin Manufacturing
Principal Product	Plastic Resins
Sales	$ 3,000,000
# of Employees	13
Plant Area (Sq.Ft.)	52,000
Annual Production	7,000,000 Pounds
Production Hrs. Annual	2,470
Location (State)	MI
Yearly Energy Cost	$ 120,144

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	1,319,089 kWh	$ 107,011	$ 0.081 /kWh
- Electricity Fees	-	$ 168	-
Natural Gas	2,315 MMBtu	$ 12,965	$ 5.60 /MMBtu
TOTAL ENERGY	15,836 MMBtu	$ 120,144	$ 7.59 /MMBtu
Water Disposal	40,635 Gal	$ 7,000	$ 0 /Gal

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	-1,080,888 kWh 0 kWh	$ -87,739 $ 0	-81.99 % 0.00 %	$ 0.081 /kWh
- Electricity Fees	-	$ 26,499 $ 0	15,773.21 % 0.00 %	-
Natural Gas	0 MMBtu 0 MMBtu	$ 0 $ 0	0.00 % 0.00 %	$ 5.60 /MMBtu
TOTAL ENERGY	-11,079 MMBtu 0 MMBtu	$ -61,240 $ 0	-50.97 % 0.00 %	$ 7.59 /MMBtu
Water Disposal	0 Gal 0 Gal	$ 0 $ 0	0.00 % 0.00 %	$ 0 /Gal

Recommendations

AR #		Description	ARC Code	Status	Cost	Savings	Payback (Years)
01	view details	ADOPT IN-HOUSE MATERIAL GENERATION	4.2120	N	$ 30,000	$ 101,745	0.29
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity -1,137,104 kWh $ -92,255 $ 0.081 /kWh TOTAL ENERGY -11,655 MMBtu $ -92,255 - Ancillary Material Cost - $ 194,000 - TOTAL PRODUCTON - $ 194,000 -
02	view details	SIZE TRUCKS TO JOB	2.8222	I	$ 54,000	$ 76,800	0.70
Energy Sources Yearly Reduction Yearly Savings Unit Price Administrative Changes - $ 76,800 - TOTAL PRODUCTON - $ 76,800 -
03	view details	REPLACE OVER-SIZE MOTORS AND PUMPS WITH OPTIMUM SIZE	2.4131	N	$ 2,477	$ 582	4.26
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 7,712 kWh $ 582 $ 0.081 /kWh TOTAL ENERGY 79 MMBtu $ 582 -
04	view details	SHIFT FROM DAYTIME TO NIGHTTIME OPERATION	2.3134	N	$ 51,860	$ 26,499	1.96
Energy Sources Yearly Reduction Yearly Savings Unit Price - Electricity Fees - $ 26,499 - TOTAL ENERGY 0 MMBtu $ 26,499 -
05	view details	INSULATE BARE EQUIPMENT	2.2511	I	$ 521	$ 2,023	0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price Ancillary Material Cost - $ 2,023 - TOTAL PRODUCTON - $ 2,023 -
06	view details	UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS	2.7142	N	$ 13,221	$ 3,934	3.36
Energy Sources Yearly Reduction Yearly Savings Unit Price Electricity 48,504 kWh $ 3,934 $ 0.081 /kWh TOTAL ENERGY 497 MMBtu $ 3,934 -

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