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

Industrial Assessment Centers

Assessment #WI0518


Assessment Year 2006
SIC 2752
SIC Description Commercial Printing, Lithographic
NAICS 0
NAICS Description
Principal Product printing books
Sales $ 40,000,000
# of Employees 327
Plant Area (Sq.Ft.) 240,000
Annual Production 40,000,000 Pounds
Production Hrs. Annual 6,000
Location (State) WI
Yearly Energy Cost $ 586,826

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 79,608,000 kWh $ 291,291 $ 0.004 /kWh

- Demand Charge

 22,520 kW $ 186,487 $ 8.28 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 9,937 MMBtu $ 109,048 $ 10.97 /MMBtu

TOTAL ENERGY

 825,919 MMBtu $ 586,826 $ 0.71 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 299,031 kWh
83,546 kWh		 $ 11,282
$ 3,207		 3.87 %
1.10 %		 $ 0.004 /kWh

- Demand Charge

 1,576 kW
950 kW		 $ 14,042
$ 7,592		 7.53 %
4.07 %		 $ 8.28 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,354 MMBtu
0 MMBtu		 $ 14,585
$ 0		 13.37 %
0.00 %		 $ 10.97 /MMBtu

TOTAL ENERGY

 4,420 MMBtu
857 MMBtu		 $ 39,909
$ 10,799		 6.80 %
1.84 %		 $ 0.71 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 IMPROVE SPACE COMFORT CONDITIONING 4.4240 I $ 4,975 $ 39,412 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 39,412 -

TOTAL PRODUCTON

 - $ 39,412 -
02 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 11,000 $ 14,585 0.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,354 MMBtu $ 14,585 $ 10.97 /MMBtu

TOTAL ENERGY

 1,354 MMBtu $ 14,585 -
03 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 0 $ 5,873 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 722 kW $ 5,873 $ 8.28 /kW

TOTAL ENERGY

 0 MMBtu $ 5,873 -
04 view
details		 INSTALL SET-BACK TIMERS 2.6232 N $ 1,400 $ 4,978 0.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 489 kW $ 4,978 $ 8.28 /kW

TOTAL ENERGY

 0 MMBtu $ 4,978 -
05 view
details		 REPLACE EXISTING CHILLER WITH HIGH EFFICIENCY MODEL 2.2622 N $ 7,000 $ 4,862 1.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 126,612 kWh $ 4,862 $ 0.004 /kWh

TOTAL ENERGY

 1,298 MMBtu $ 4,862 -
06 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 1,630 $ 3,802 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 60,674 kWh $ 2,330 $ 0.004 /kWh

- Demand Charge

 137 kW $ 1,472 $ 8.28 /kW

TOTAL ENERGY

 622 MMBtu $ 3,802 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 2,560 $ 1,994 1.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,625 kWh $ 1,214 $ 0.004 /kWh

- Demand Charge

 90 kW $ 780 $ 8.28 /kW

TOTAL ENERGY

 324 MMBtu $ 1,994 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 0 $ 1,722 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 30,213 kWh $ 1,160 $ 0.004 /kWh

- Demand Charge

 90 kW $ 562 $ 8.28 /kW

TOTAL ENERGY

 310 MMBtu $ 1,722 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 778 $ 1,210 0.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,708 kWh $ 833 $ 0.004 /kWh

- Demand Charge

 48 kW $ 377 $ 8.28 /kW

TOTAL ENERGY

 223 MMBtu $ 1,210 -
10 view
details		 MAINTAIN AIR FILTERS BY CLEANING OR REPLACEMENT 2.6127 N $ 0 $ 883 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,199 kWh $ 883 $ 0.004 /kWh

TOTAL ENERGY

 289 MMBtu $ 883 -