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

Industrial Assessment Centers

Assessment #WI0490


Assessment Year 2005
SIC 3677
SIC Description Electronic Coils And Transformers
NAICS 325212
NAICS Description Synthetic Rubber Manufacturing
Principal Product Urethane couplings and sprockets
Sales $ 18,000,000
# of Employees 78
Plant Area (Sq.Ft.) 125,000
Annual Production 260,000 Pieces
Production Hrs. Annual 4,000
Location (State) WI
Yearly Energy Cost $ 409,532

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,761,040 kWh $ 124,953 $ 0.033 /kWh

- Demand Charge

 11,444 kW $ 97,263 $ 8.50 /kW

- Electricity Fees

 - $ 42,238 -

Natural Gas

 19,699 MMBtu $ 145,078 $ 7.36 /MMBtu

TOTAL ENERGY

 58,250 MMBtu $ 409,532 $ 7.03 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 -208,876 kWh
25,954 kWh		 $ -7,293
$ 905		 -5.84 %
0.72 %		 $ 0.033 /kWh

- Demand Charge

 -612 kW
70 kW		 $ -5,465
$ 627		 -5.62 %
0.64 %		 $ 8.50 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 7.36 /MMBtu

TOTAL ENERGY

 -2,141 MMBtu
266 MMBtu		 $ -12,758
$ 1,532		 -3.12 %
0.37 %		 $ 7.03 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 IMPROVE SPACE COMFORT CONDITIONING 4.4240 N $ 360,000 $ 260,463 1.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -332,357 kWh $ -11,600 $ 0.033 /kWh

- Demand Charge

 -989 kW $ -8,833 $ 8.50 /kW

TOTAL ENERGY

 -3,407 MMBtu $ -20,433 -

Personnel Changes

 - $ 280,896 -

TOTAL PRODUCTON

 - $ 280,896 -
02 view
details		 INSTALL AUTOMATIC PACKING EQUIPMENT 4.4410 N $ 75,000 $ 85,979 0.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -14,920 kWh $ -521 $ 0.033 /kWh

- Demand Charge

 -34 kW $ -300 $ 8.50 /kW

TOTAL ENERGY

 -153 MMBtu $ -821 -

Personnel Changes

 - $ 88,000 -

Ancillary Material Cost

 - $ -1,200 -

TOTAL PRODUCTON

 - $ 86,800 -
03 view
details		 TRAIN OPERATORS FOR MAXIMUM OPERATING EFFICIENCY 4.4310 I $ 1,000 $ 7,000 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ -1,000 -

One-time Revenue or Avoided Cost

 - $ 8,000 -

TOTAL PRODUCTON

 - $ 7,000 -
04 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 18,900 $ 6,347 2.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 102,900 kWh $ 3,590 $ 0.033 /kWh

- Demand Charge

 309 kW $ 2,757 $ 8.50 /kW

TOTAL ENERGY

 1,055 MMBtu $ 6,347 -
05 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 640 $ 617 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,547 kWh $ 333 $ 0.033 /kWh

- Demand Charge

 32 kW $ 284 $ 8.50 /kW

TOTAL ENERGY

 98 MMBtu $ 617 -
06 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 I $ 1,165 $ 538 2.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,682 kWh $ 408 $ 0.033 /kWh

- Demand Charge

 15 kW $ 130 $ 8.50 /kW

TOTAL ENERGY

 120 MMBtu $ 538 -
07 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 361 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,361 kWh $ 361 $ 0.033 /kWh

TOTAL ENERGY

 106 MMBtu $ 361 -
08 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 227 $ 317 0.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,357 kWh $ 117 $ 0.033 /kWh

- Demand Charge

 22 kW $ 200 $ 8.50 /kW

TOTAL ENERGY

 34 MMBtu $ 317 -
09 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 52 $ 316 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 554 kWh $ 19 $ 0.033 /kWh

- Demand Charge

 33 kW $ 297 $ 8.50 /kW

TOTAL ENERGY

 6 MMBtu $ 316 -