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

Industrial Assessment Centers

Assessment #WI0495


Assessment Year 2005
SIC 2631
SIC Description Paperboard Mills
NAICS 322130
NAICS Description Paperboard Mills
Principal Product Cardboard boxes
Sales $ 25,000,000
# of Employees 80
Plant Area (Sq.Ft.) 189,000
Annual Production 1,700,000 Pounds
Production Hrs. Annual 6,000
Location (State) WI
Yearly Energy Cost $ 678,619

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,966,600 kWh $ 159,605 $ 0.032 /kWh

- Demand Charge

 11,707 kW $ 89,316 $ 7.63 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 60,173 MMBtu $ 429,698 $ 7.14 /MMBtu

TOTAL ENERGY

 111,081 MMBtu $ 678,619 $ 6.11 /MMBtu

Solid Waste (non-haz)

 1,000,000 lbs $ 5,184 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 5,807,834 kWh
285,180 kWh		 $ 196,885
$ 9,668		 123.36 %
6.06 %		 $ 0.032 /kWh

- Demand Charge

 11,746 kW
869 kW		 $ 94,555
$ 6,995		 105.87 %
7.83 %		 $ 7.63 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -14,408 MMBtu
624 MMBtu		 $ -102,873
$ 4,455		 -23.94 %
1.04 %		 $ 7.14 /MMBtu

TOTAL ENERGY

 45,122 MMBtu
3,547 MMBtu		 $ 188,567
$ 21,118		 27.79 %
3.11 %		 $ 6.11 /MMBtu

Solid Waste (non-haz)

 0 lbs
0 lbs		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE A FOSSIL FUEL ENGINE TO COGENERATE ELECTRICITY OR MOTIVE POWER; AND UTILIZE HEAT 2.3415 N $ 360,000 $ 162,672 2.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,400,000 kWh $ 183,060 $ 0.032 /kWh

- Demand Charge

 10,800 kW $ 86,940 $ 7.63 /kW

Natural Gas

 -15,032 MMBtu $ -107,328 $ 7.14 /MMBtu

TOTAL ENERGY

 40,318 MMBtu $ 162,672 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 32,760 $ 14,256 2.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 285,180 kWh $ 9,668 $ 0.032 /kWh

- Demand Charge

 570 kW $ 4,588 $ 7.63 /kW

TOTAL ENERGY

 2,923 MMBtu $ 14,256 -
03 view
details		 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA 2.7221 I $ 360 $ 3,320 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 465 MMBtu $ 3,320 $ 7.14 /MMBtu

TOTAL ENERGY

 465 MMBtu $ 3,320 -
04 view
details		 INSTALL AUTOMATIC STACK DAMPER 2.1123 N $ 3,400 $ 2,655 1.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 78,330 kWh $ 2,655 $ 0.032 /kWh

TOTAL ENERGY

 803 MMBtu $ 2,655 -
05 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 0 $ 2,165 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 269 kW $ 2,165 $ 7.63 /kW

TOTAL ENERGY

 0 MMBtu $ 2,165 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,280 $ 1,800 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 34,813 kWh $ 1,180 $ 0.032 /kWh

- Demand Charge

 77 kW $ 620 $ 7.63 /kW

TOTAL ENERGY

 357 MMBtu $ 1,800 -
07 view
details		 USE WASTE HEAT FROM FLUE GASES TO HEAT SPACE CONDITIONING AIR 2.2426 I $ 1,500 $ 1,135 1.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 159 MMBtu $ 1,135 $ 7.14 /MMBtu

TOTAL ENERGY

 159 MMBtu $ 1,135 -
08 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 N $ 150 $ 322 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,511 kWh $ 322 $ 0.032 /kWh

TOTAL ENERGY

 97 MMBtu $ 322 -
09 view
details		 RECHARGE BATTERIES ON DURING OFF-PEAK DEMAND PERIODS 2.3132 I $ 200 $ 242 0.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 30 kW $ 242 $ 7.63 /kW

TOTAL ENERGY

 0 MMBtu $ 242 -