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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #UM0371


Assessment Year 2010
SIC 3544
SIC Description Special Dies, Tools, Jigs & Fixtures
NAICS 333511
NAICS Description Industrial Mold Manufacturing
Principal Product Large Stamping Dies
Sales $ 40,000,000
# of Employees 260
Plant Area (Sq.Ft.) 360,000
Annual Production 300 Not Available
Production Hrs. Annual 6,396
Location (State) MI
Yearly Energy Cost $ 860,127

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 8,994,166 kWh $ 475,980 $ 0.053 /kWh

- Demand Charge

 21,623 kW $ 322,542 $ 14.92 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 5,897 MMBtu $ 61,605 $ 10.45 /MMBtu

TOTAL ENERGY

 98,087 MMBtu $ 860,127 $ 8.77 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 690,782 kWh
690,782 kWh		 $ 36,555
$ 36,555		 7.68 %
7.68 %		 $ 0.053 /kWh

- Demand Charge

 4,232 kW
4,232 kW		 $ 63,149
$ 63,149		 19.58 %
19.58 %		 $ 14.92 /kW

- Electricity Fees

 - $ 60,000
$ 60,000		 0.00 %
0.00 %		 -

Natural Gas

 912 MMBtu
0 MMBtu		 $ 9,530
$ 0		 15.47 %
0.00 %		 $ 10.45 /MMBtu

TOTAL ENERGY

 7,992 MMBtu
7,080 MMBtu		 $ 169,234
$ 159,704		 19.68 %
18.57 %		 $ 8.77 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 I $ 1,319,976 $ 70,732 18.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 258,183 kWh $ 13,663 $ 0.053 /kWh

- Demand Charge

 3,825 kW $ 57,069 $ 14.92 /kW

TOTAL ENERGY

 2,646 MMBtu $ 70,732 -
02 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 I $ 50,000 $ 60,000 0.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 60,000 -

TOTAL ENERGY

 0 MMBtu $ 60,000 -
03 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 3,128 $ 18,676 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 352,921 kWh $ 18,676 $ 0.053 /kWh

TOTAL ENERGY

 3,617 MMBtu $ 18,676 -
04 view
details		 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES 2.6211 I $ 10 $ 4,729 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,400 kWh $ 1,238 $ 0.053 /kWh

- Demand Charge

 234 kW $ 3,491 $ 14.92 /kW

TOTAL ENERGY

 240 MMBtu $ 4,729 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 35,268 $ 3,092 11.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,654 kWh $ 1,358 $ 0.053 /kWh

- Demand Charge

 116 kW $ 1,734 $ 14.92 /kW

TOTAL ENERGY

 263 MMBtu $ 3,092 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 3,500 $ 2,475 1.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 30,624 kWh $ 1,620 $ 0.053 /kWh

- Demand Charge

 57 kW $ 855 $ 14.92 /kW

TOTAL ENERGY

 314 MMBtu $ 2,475 -
07 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 300,000 $ 9,530 31.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 912 MMBtu $ 9,530 $ 10.45 /MMBtu

TOTAL ENERGY

 912 MMBtu $ 9,530 -