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

Industrial Assessment Centers

Assessment #WV0374


Assessment Year 2008
SIC 3545
SIC Description Machine Tool Accessories
NAICS 332212
NAICS Description Hand and Edge Tool Manufacturing
Principal Product Cutting Tools
Sales $ 20,000,000
# of Employees 250
Plant Area (Sq.Ft.) 74,000
Annual Production 1,820,000 Pieces
Production Hrs. Annual 8,712
Location (State) OH
Yearly Energy Cost $ 811,264

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,379,000 kWh $ 804,089 $ 0.077 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 3,181 MMBtu $ 7,175 $ 2.26 /MMBtu

TOTAL ENERGY

 109,566 MMBtu $ 811,264 $ 7.40 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 974,280 kWh
851,068 kWh		 $ 81,039
$ 65,932		 10.08 %
8.20 %		 $ 0.077 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,404 MMBtu
0 MMBtu		 $ 3,173
$ 0		 44.22 %
0.00 %		 $ 2.26 /MMBtu

TOTAL ENERGY

 11,389 MMBtu
8,723 MMBtu		 $ 84,212
$ 65,932		 10.38 %
8.13 %		 $ 7.40 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 12,730 $ 25,144 0.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 324,567 kWh $ 25,144 $ 0.077 /kWh

TOTAL ENERGY

 3,327 MMBtu $ 25,144 -
02 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 2,213 $ 15,831 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 204,351 kWh $ 15,831 $ 0.077 /kWh

TOTAL ENERGY

 2,095 MMBtu $ 15,831 -
03 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 4,500 $ 7,994 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 108,144 kWh $ 8,378 $ 0.077 /kWh

TOTAL ENERGY

 1,108 MMBtu $ 8,378 -

Personnel Changes

 - $ -384 -

TOTAL PRODUCTON

 - $ -384 -
04 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 1,076 $ 7,339 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 96,127 kWh $ 7,447 $ 0.077 /kWh

TOTAL ENERGY

 985 MMBtu $ 7,447 -

Personnel Changes

 - $ -108 -

TOTAL PRODUCTON

 - $ -108 -
05 view
details		 USE POWER FACTOR CONTROLLERS 2.3211 N $ 11,346 $ 5,562 2.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 0 kWh $ 5,562 $ 0.077 /kWh

TOTAL ENERGY

 0 MMBtu $ 5,562 -
06 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 6,378 $ 5,079 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 72,534 kWh $ 5,619 $ 0.077 /kWh

TOTAL ENERGY

 743 MMBtu $ 5,619 -

Personnel Changes

 - $ -540 -

TOTAL PRODUCTON

 - $ -540 -
07 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 612 $ 4,440 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 57,317 kWh $ 4,440 $ 0.077 /kWh

TOTAL ENERGY

 587 MMBtu $ 4,440 -
08 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 315 $ 3,513 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 45,345 kWh $ 3,513 $ 0.077 /kWh

TOTAL ENERGY

 465 MMBtu $ 3,513 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 9,054 $ 3,039 2.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,232 kWh $ 3,039 $ 0.077 /kWh

TOTAL ENERGY

 402 MMBtu $ 3,039 -
10 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 440 $ 2,784 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,232 MMBtu $ 2,784 $ 2.26 /MMBtu

TOTAL ENERGY

 1,232 MMBtu $ 2,784 -
11 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 1,884 $ 1,750 1.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,663 kWh $ 2,066 $ 0.077 /kWh

TOTAL ENERGY

 273 MMBtu $ 2,066 -

Personnel Changes

 - $ -316 -

TOTAL PRODUCTON

 - $ -316 -
12 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 690 $ 389 1.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 172 MMBtu $ 389 $ 2.26 /MMBtu

TOTAL ENERGY

 172 MMBtu $ 389 -