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

Industrial Assessment Centers

Assessment #WV0312


Assessment Year 2005
SIC 3089
SIC Description Plastics Products, Nec
NAICS 312221
NAICS Description Cigarette Manufacturing
Principal Product Printing and Cutting of Cardboard Boxes
Sales $ 6,000,000
# of Employees 200
Plant Area (Sq.Ft.) 120,000
Annual Production 50,000,000 Pieces
Production Hrs. Annual 8,568
Location (State) VA
Yearly Energy Cost $ 987,054

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,720,000 kWh $ 214,568 $ 0.022 /kWh

- Demand Charge

 16,529 kW $ 136,367 $ 8.25 /kW

- Electricity Fees

 - $ 7,892 -

Natural Gas

 66,629 MMBtu $ 628,227 $ 9.43 /MMBtu

TOTAL ENERGY

 166,259 MMBtu $ 987,054 $ 5.94 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,644,245 kWh
875,844 kWh		 $ 37,676
$ 20,078		 17.56 %
9.36 %		 $ 0.022 /kWh

- Demand Charge

 2,392 kW
1,330 kW		 $ 19,710
$ 10,959		 14.45 %
8.04 %		 $ 8.25 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,598 MMBtu
0 MMBtu		 $ 15,023
$ 0		 2.39 %
0.00 %		 $ 9.43 /MMBtu

TOTAL ENERGY

 18,452 MMBtu
8,977 MMBtu		 $ 72,409
$ 31,037		 7.34 %
3.14 %		 $ 5.94 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 6,435 $ 15,023 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,598 MMBtu $ 15,023 $ 9.43 /MMBtu

TOTAL ENERGY

 1,598 MMBtu $ 15,023 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 18,750 $ 14,049 1.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 384,573 kWh $ 8,810 $ 0.022 /kWh

- Demand Charge

 635 kW $ 5,239 $ 8.25 /kW

TOTAL ENERGY

 3,942 MMBtu $ 14,049 -
03 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 N $ 9,600 $ 14,013 0.69
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 406,690 kWh $ 9,314 $ 0.022 /kWh

- Demand Charge

 570 kW $ 4,699 $ 8.25 /kW

TOTAL ENERGY

 4,169 MMBtu $ 14,013 -
04 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 2,970 $ 6,107 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 177,265 kWh $ 4,059 $ 0.022 /kWh

- Demand Charge

 248 kW $ 2,048 $ 8.25 /kW

TOTAL ENERGY

 1,817 MMBtu $ 6,107 -
05 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 N $ 7,480 $ 5,641 1.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 167,408 kWh $ 3,834 $ 0.022 /kWh

- Demand Charge

 219 kW $ 1,807 $ 8.25 /kW

TOTAL ENERGY

 1,716 MMBtu $ 5,641 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 250 $ 4,708 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 136,639 kWh $ 3,129 $ 0.022 /kWh

- Demand Charge

 191 kW $ 1,579 $ 8.25 /kW

TOTAL ENERGY

 1,401 MMBtu $ 4,708 -
07 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 N $ 413 $ 3,672 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 127,455 kWh $ 2,919 $ 0.022 /kWh

- Demand Charge

 179 kW $ 1,473 $ 8.25 /kW

TOTAL ENERGY

 1,306 MMBtu $ 4,392 -

Personnel Changes

 - $ -720 -

TOTAL PRODUCTON

 - $ -720 -
08 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 4,800 $ 2,210 2.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 63,872 kWh $ 1,476 $ 0.022 /kWh

- Demand Charge

 89 kW $ 734 $ 8.25 /kW

TOTAL ENERGY

 655 MMBtu $ 2,210 -
09 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 2,788 $ 1,797 1.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 51,568 kWh $ 1,181 $ 0.022 /kWh

- Demand Charge

 77 kW $ 616 $ 8.25 /kW

TOTAL ENERGY

 529 MMBtu $ 1,797 -
10 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 824 $ 1,712 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 49,707 kWh $ 1,138 $ 0.022 /kWh

- Demand Charge

 70 kW $ 574 $ 8.25 /kW

TOTAL ENERGY

 509 MMBtu $ 1,712 -
11 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 0 $ 1,460 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,336 kWh $ 973 $ 0.022 /kWh

- Demand Charge

 59 kW $ 487 $ 8.25 /kW

TOTAL ENERGY

 434 MMBtu $ 1,460 -
12 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 I $ 120 $ 706 0.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,591 kWh $ 450 $ 0.022 /kWh

- Demand Charge

 31 kW $ 256 $ 8.25 /kW

TOTAL ENERGY

 201 MMBtu $ 706 -
13 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 130 $ 591 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,141 kWh $ 393 $ 0.022 /kWh

- Demand Charge

 24 kW $ 198 $ 8.25 /kW

TOTAL ENERGY

 176 MMBtu $ 591 -