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U.S. Department of Energy Energy Efficiency and Renewable Energy
IAC Field Managers

Industrial Assessment Centers

Assessment #WI0286


Assessment Year 1997
SIC 3589
SIC Description Service Industry Machinery, Nec
NAICS
NAICS Description
Principal Product Water treatment equipment
Sales $ 35,000,000
# of Employees 301
Plant Area (Sq.Ft.) 207,500
Annual Production 100 Pieces
Production Hrs. Annual 4,250
Location (State) WI
Yearly Energy Cost $ 392,836

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,388,335 kWh $ 189,455 $ 0.043 /kWh

- Demand Charge

 9,150 kW $ 68,992 $ 7.54 /kW

- Electricity Fees

 - $ 14,785 -

Natural Gas

 39,929 MMBtu $ 119,604 $ 3.00 /MMBtu

TOTAL ENERGY

 84,909 MMBtu $ 392,836 $ 4.63 /MMBtu

Water Disposal

 2,158,500 Gal $ 9,218 $ 0 /Gal

Solid Waste (non-haz)

 551,250 lbs $ 6,000 $ 0 /lbs

Solid Waste (haz)

 18,040 lbs $ 14,175 $ 0 /lbs

Gaseous Waste

 2,370 lbs $ 0 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 348,181 kWh
0 kWh		 $ 8,989
$ 0		 4.74 %
0.00 %		 $ 0.043 /kWh

- Demand Charge

 4,250 kW
0 kW		 $ 33,673
$ 0		 48.81 %
0.00 %		 $ 7.54 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 9,596 MMBtu
0 MMBtu		 $ 30,085
$ 0		 25.15 %
0.00 %		 $ 3.00 /MMBtu

TOTAL ENERGY

 13,164 MMBtu
0 MMBtu		 $ 72,747
$ 0		 18.52 %
0.00 %		 $ 4.63 /MMBtu

Water Disposal

 927,750 Gal
0 Gal		 $ -3,441
$ 0		 -37.33 %
0.00 %		 $ 0 /Gal

Solid Waste (non-haz)

 264 lbs
0 lbs		 $ 953
$ 0		 15.88 %
0.00 %		 $ 0 /lbs

Solid Waste (haz)

 425 lbs
0 lbs		 $ 5,619
$ 0		 39.64 %
0.00 %		 $ 0 /lbs

Gaseous Waste

 2,370 lbs
0 lbs		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 CONVERT TO HIGH VOLUME LOW PRESSURE (HVLP) PAINT GUNS 3.2123 N $ 1,000 $ 29,011 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (haz)

 425 lbs $ 3,481 $ 0 /lbs

TOTAL WASTE

 - $ 3,481 -

Primary Raw Material

 - $ 25,530 -

TOTAL PRODUCTON

 - $ 25,530 -
02 view
details		 REDUCE VENTILATION AIR 2.7314 N $ 1,000 $ 6,908 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,309 kWh $ 321 $ 0.043 /kWh

Natural Gas

 1,709 MMBtu $ 6,587 $ 3.00 /MMBtu

TOTAL ENERGY

 1,835 MMBtu $ 6,908 -
03 view
details		 USE TIGHT-FITTING LIDS ON MATERIAL CONTAINERS TO REDUCE VOC EMISSIONS 3.8122 N $ 1,000 $ 2,999 0.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 750 -

Primary Raw Material

 - $ 2,249 -

TOTAL PRODUCTON

 - $ 2,999 -
04 view
details		 INSTALL EQUIPMENT (eg COMPACTOR) TO REDUCE DISPOSAL COSTS 3.6193 N $ 5,000 $ 2,138 2.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (haz)

 0 lbs $ 2,138 $ 0 /lbs

TOTAL WASTE

 - $ 2,138 -
05 view
details		 SHIFT FROM DAYTIME TO NIGHTTIME OPERATION 2.3134 N $ 0 $ 26,499 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 3,522 kW $ 27,899 $ 7.54 /kW

TOTAL ENERGY

 0 MMBtu $ 27,899 -

Personnel Changes

 - $ -1,400 -

TOTAL PRODUCTON

 - $ -1,400 -
06 view
details		 REPLACE EXISTING HVAC UNIT WITH HIGH EFFICIENCY MODEL 2.7232 N $ 88,000 $ 19,520 4.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,561 MMBtu $ 4,520 $ 3.00 /MMBtu

TOTAL ENERGY

 1,561 MMBtu $ 4,520 -

Personnel Changes

 - $ 15,000 -

TOTAL PRODUCTON

 - $ 15,000 -
07 view
details		 MODIFY REFRIGERATION SYSTEM TO OPERATE AT A LOWER PRESSURE 2.2621 N $ 15,000 $ 6,085 2.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 152,989 kWh $ 3,947 $ 0.043 /kWh

- Demand Charge

 270 kW $ 2,138 $ 7.54 /kW

TOTAL ENERGY

 1,568 MMBtu $ 6,085 -
08 view
details		 REDUCE AIR CONDITIONING LOAD BY EVAPORATING WATER FROM ROOF 2.7251 N $ 10,230 $ 2,230 4.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 117,526 kWh $ 3,034 $ 0.043 /kWh

- Demand Charge

 367 kW $ 2,911 $ 7.54 /kW

TOTAL ENERGY

 1,205 MMBtu $ 5,945 -

Water Disposal

 864,000 Gal $ -3,715 $ 0 /Gal

TOTAL WASTE

 - $ -3,715 -
09 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 N $ 3,600 $ 18,978 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,326 MMBtu $ 18,978 $ 3.00 /MMBtu

TOTAL ENERGY

 6,326 MMBtu $ 18,978 -
10 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 210 $ 1,310 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 30,774 kWh $ 794 $ 0.043 /kWh

- Demand Charge

 65 kW $ 516 $ 7.54 /kW

TOTAL ENERGY

 315 MMBtu $ 1,310 -
11 view
details		 MINIMIZE WATER USAGE 3.4151 N $ 0 $ 274 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 63,750 Gal $ 274 $ 0 /Gal

TOTAL WASTE

 - $ 274 -
12 view
details		 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER 3.5315 N $ 0 $ 953 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 264 lbs $ 953 $ 0 /lbs

TOTAL WASTE

 - $ 953 -
13 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 450 $ 575 0.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,274 kWh $ 575 $ 0.043 /kWh

TOTAL ENERGY

 228 MMBtu $ 575 -
14 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 328 $ 527 0.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,309 kWh $ 318 $ 0.043 /kWh

- Demand Charge

 26 kW $ 209 $ 7.54 /kW

TOTAL ENERGY

 126 MMBtu $ 527 -