U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #WV0443


Assessment Year 2012
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Automobile Plastic Parts
Sales $ 120,000,000
# of Employees 565
Plant Area (Sq.Ft.) 425,000
Annual Production 120,000,000 Pounds
Production Hrs. Annual 8,064
Location (State) OH
Yearly Energy Cost $ 3,380,075

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 31,608,216 kWh $ 1,996,901 $ 0.063 /kWh

- Demand Charge

 63,092 kW $ 504,774 $ 8.00 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 148,210 MMBtu $ 878,400 $ 5.93 /MMBtu

TOTAL ENERGY

 472,197 MMBtu $ 3,380,075 $ 7.16 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 5,309,567 kWh
1,949,302 kWh		 $ 335,458
$ 123,157		 16.80 %
6.17 %		 $ 0.063 /kWh

- Demand Charge

 7,841 kW
2,903 kW		 $ 62,568
$ 23,064		 12.40 %
4.57 %		 $ 8.00 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 9,567 MMBtu
1,583 MMBtu		 $ 56,732
$ 9,387		 6.46 %
1.07 %		 $ 5.93 /MMBtu

TOTAL ENERGY

 63,991 MMBtu
21,564 MMBtu		 $ 454,758
$ 155,608		 13.45 %
4.60 %		 $ 7.16 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 102,956 $ 186,348 0.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,478,569 kWh $ 156,596 $ 0.063 /kWh

- Demand Charge

 3,719 kW $ 29,752 $ 8.00 /kW

TOTAL ENERGY

 25,406 MMBtu $ 186,348 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 160,057 $ 59,316 2.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 789,937 kWh $ 49,908 $ 0.063 /kWh

- Demand Charge

 1,196 kW $ 9,408 $ 8.00 /kW

TOTAL ENERGY

 8,097 MMBtu $ 59,316 -
03 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 6,000 $ 39,551 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 537,814 kWh $ 33,979 $ 0.063 /kWh

- Demand Charge

 800 kW $ 6,400 $ 8.00 /kW

TOTAL ENERGY

 5,513 MMBtu $ 40,379 -

Personnel Changes

 - $ -828 -

TOTAL PRODUCTON

 - $ -828 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 32,050 $ 30,777 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 487,138 kWh $ 30,777 $ 0.063 /kWh

TOTAL ENERGY

 4,993 MMBtu $ 30,777 -
05 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 5,551 $ 25,750 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 370,906 kWh $ 23,434 $ 0.063 /kWh

- Demand Charge

 552 kW $ 4,416 $ 8.00 /kW

TOTAL ENERGY

 3,802 MMBtu $ 27,850 -

Personnel Changes

 - $ -2,100 -

TOTAL PRODUCTON

 - $ -2,100 -
06 view
details		 USE WASTE HEAT FROM FLUE GASES TO HEAT SPACE CONDITIONING AIR 2.2426 N $ 43,600 $ 22,024 1.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,714 MMBtu $ 22,024 $ 5.93 /MMBtu

TOTAL ENERGY

 3,714 MMBtu $ 22,024 -
07 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 34,000 $ 16,138 2.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 131,344 kWh $ 8,298 $ 0.063 /kWh

- Demand Charge

 980 kW $ 7,840 $ 8.00 /kW

TOTAL ENERGY

 1,346 MMBtu $ 16,138 -
08 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 31,450 $ 13,230 2.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,231 MMBtu $ 13,230 $ 5.93 /MMBtu

TOTAL ENERGY

 2,231 MMBtu $ 13,230 -
09 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 40,725 $ 9,998 4.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,686 MMBtu $ 9,998 $ 5.93 /MMBtu

TOTAL ENERGY

 1,686 MMBtu $ 9,998 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 2,000 $ 9,620 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 128,078 kWh $ 8,092 $ 0.063 /kWh

- Demand Charge

 191 kW $ 1,528 $ 8.00 /kW

TOTAL ENERGY

 1,313 MMBtu $ 9,620 -
11 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 N $ 10,700 $ 6,831 1.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 108,117 kWh $ 6,831 $ 0.063 /kWh

TOTAL ENERGY

 1,108 MMBtu $ 6,831 -
12 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 5,175 $ 6,825 0.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 90,933 kWh $ 5,745 $ 0.063 /kWh

- Demand Charge

 135 kW $ 1,080 $ 8.00 /kW

TOTAL ENERGY

 932 MMBtu $ 6,825 -
13 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 I $ 6,738 $ 5,366 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,141 MMBtu $ 6,766 $ 5.93 /MMBtu

TOTAL ENERGY

 1,141 MMBtu $ 6,766 -

Personnel Changes

 - $ -1,400 -

TOTAL PRODUCTON

 - $ -1,400 -
14 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 998 $ 5,361 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 71,407 kWh $ 4,511 $ 0.063 /kWh

- Demand Charge

 106 kW $ 850 $ 8.00 /kW

TOTAL ENERGY

 732 MMBtu $ 5,361 -
15 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 1,000 $ 5,236 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,734 kWh $ 4,406 $ 0.063 /kWh

- Demand Charge

 104 kW $ 830 $ 8.00 /kW

TOTAL ENERGY

 715 MMBtu $ 5,236 -
16 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 6,840 $ 2,093 3.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 353 MMBtu $ 2,093 $ 5.93 /MMBtu

TOTAL ENERGY

 353 MMBtu $ 2,093 -
17 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 N $ 1,255 $ 2,091 0.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 27,019 kWh $ 1,707 $ 0.063 /kWh

- Demand Charge

 48 kW $ 384 $ 8.00 /kW

TOTAL ENERGY

 277 MMBtu $ 2,091 -
18 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 4,020 $ 1,749 2.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,803 kWh $ 430 $ 0.063 /kWh

- Demand Charge

 10 kW $ 80 $ 8.00 /kW

Natural Gas

 209 MMBtu $ 1,239 $ 5.93 /MMBtu

TOTAL ENERGY

 279 MMBtu $ 1,749 -
19 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 2,500 $ 1,224 2.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 233 MMBtu $ 1,382 $ 5.93 /MMBtu

TOTAL ENERGY

 233 MMBtu $ 1,382 -

Personnel Changes

 - $ -158 -

TOTAL PRODUCTON

 - $ -158 -
20 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 1,058 $ 744 1.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,768 kWh $ 744 $ 0.063 /kWh

TOTAL ENERGY

 121 MMBtu $ 744 -