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

Industrial Assessment Centers

Assessment #WV0335


Assessment Year 2006
SIC 2752
SIC Description Commercial Printing, Lithographic
NAICS 323114
NAICS Description Quick Printing
Principal Product Printed Materials
Sales $ 50,000,000
# of Employees 200
Plant Area (Sq.Ft.) 110,000
Annual Production 900,000,000 Pieces
Production Hrs. Annual 8,760
Location (State) OH
Yearly Energy Cost $ 1,779,262

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 14,400,000 kWh $ 654,685 $ 0.045 /kWh

- Demand Charge

 37,458 kW $ 325,510 $ 8.69 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 101,443 MMBtu $ 799,067 $ 7.88 /MMBtu

TOTAL ENERGY

 249,043 MMBtu $ 1,779,262 $ 7.14 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,026,681 kWh
228,824 kWh		 $ 137,599
$ 10,406		 21.02 %
1.59 %		 $ 0.045 /kWh

- Demand Charge

 4,147 kW
314 kW		 $ 36,035
$ 2,726		 11.07 %
0.84 %		 $ 8.69 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 16,525 MMBtu
16,357 MMBtu		 $ 130,186
$ 128,896		 16.29 %
16.13 %		 $ 7.88 /MMBtu

TOTAL ENERGY

 47,548 MMBtu
18,702 MMBtu		 $ 303,820
$ 142,028		 17.08 %
7.98 %		 $ 7.14 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE WASTE HEAT STEAM FOR ABSORPTION REFRIGERATION 2.2693 N $ 97,142 $ 151,578 0.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,642,274 kWh $ 120,120 $ 0.045 /kWh

- Demand Charge

 3,620 kW $ 31,458 $ 8.69 /kW

TOTAL ENERGY

 27,083 MMBtu $ 151,578 -
02 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 I $ 14,450 $ 127,911 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 16,232 MMBtu $ 127,911 $ 7.88 /MMBtu

TOTAL ENERGY

 16,232 MMBtu $ 127,911 -
03 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 250 $ 8,924 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 155,583 kWh $ 7,073 $ 0.045 /kWh

- Demand Charge

 213 kW $ 1,851 $ 8.69 /kW

TOTAL ENERGY

 1,595 MMBtu $ 8,924 -
04 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 240 $ 6,057 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 118,079 kWh $ 5,371 $ 0.045 /kWh

- Demand Charge

 162 kW $ 1,406 $ 8.69 /kW

TOTAL ENERGY

 1,210 MMBtu $ 6,777 -

Personnel Changes

 - $ -720 -

TOTAL PRODUCTON

 - $ -720 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,420 $ 2,865 0.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 50,973 kWh $ 2,318 $ 0.045 /kWh

- Demand Charge

 70 kW $ 607 $ 8.69 /kW

TOTAL ENERGY

 522 MMBtu $ 2,925 -

Ancillary Material Cost

 - $ -60 -

TOTAL PRODUCTON

 - $ -60 -
06 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 I $ 5,803 $ 2,785 2.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 59,772 kWh $ 2,717 $ 0.045 /kWh

- Demand Charge

 82 kW $ 713 $ 8.69 /kW

TOTAL ENERGY

 613 MMBtu $ 3,430 -

Personnel Changes

 - $ -20 -

Ancillary Material Cost

 - $ -625 -

TOTAL PRODUCTON

 - $ -645 -
07 view
details		 BURN WASTE OIL FOR HEAT 3.6124 N $ 1,300 $ 1,494 0.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 168 MMBtu $ 1,290 $ 7.88 /MMBtu

TOTAL ENERGY

 168 MMBtu $ 1,290 -

Other Liquid (non-haz)

 1,200 Gal $ 204 $ 0 /Gal

TOTAL WASTE

 - $ 204 -
08 view
details		 USE PROPER THICKNESS OF INSULATION ON BUILDING ENVELOPE 2.7492 I $ 1,680 $ 985 1.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 125 MMBtu $ 985 $ 7.88 /MMBtu

TOTAL ENERGY

 125 MMBtu $ 985 -