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

Industrial Assessment Centers

Assessment #WV0445


Assessment Year 2012
SIC 3089
SIC Description Plastics Products, Nec
NAICS 326199
NAICS Description All Other Plastics Product Manufacturing
Principal Product Vinyl Siding
Sales $ 70,000,000
# of Employees 175
Plant Area (Sq.Ft.) 165,000
Annual Production 60,000,000 Pounds
Production Hrs. Annual 4,368
Location (State) WV
Yearly Energy Cost $ 926,055

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 12,824,519 kWh $ 511,119 $ 0.040 /kWh

- Demand Charge

 26,418 kW $ 359,203 $ 13.60 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 6,331 MMBtu $ 55,733 $ 8.80 /MMBtu

TOTAL ENERGY

 137,784 MMBtu $ 926,055 $ 6.72 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,217,655 kWh
248,283 kWh		 $ 48,763
$ 9,884		 9.54 %
1.93 %		 $ 0.040 /kWh

- Demand Charge

 2,299 kW
1,106 kW		 $ 31,276
$ 15,045		 8.71 %
4.19 %		 $ 13.60 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 957 MMBtu
957 MMBtu		 $ 8,421
$ 8,421		 15.11 %
15.11 %		 $ 8.80 /MMBtu

TOTAL ENERGY

 13,438 MMBtu
3,502 MMBtu		 $ 88,460
$ 33,350		 9.55 %
3.60 %		 $ 6.72 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 29,500 $ 10,833 2.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 140,640 kWh $ 5,597 $ 0.040 /kWh

- Demand Charge

 385 kW $ 5,236 $ 13.60 /kW

TOTAL ENERGY

 1,442 MMBtu $ 10,833 -
02 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 N $ 1,000 $ 9,398 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 194,177 kWh $ 7,728 $ 0.040 /kWh

- Demand Charge

 311 kW $ 4,230 $ 13.60 /kW

TOTAL ENERGY

 1,990 MMBtu $ 11,958 -

Personnel Changes

 - $ -2,560 -

TOTAL PRODUCTON

 - $ -2,560 -
03 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 15,050 $ 9,071 1.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 227,911 kWh $ 9,071 $ 0.040 /kWh

TOTAL ENERGY

 2,336 MMBtu $ 9,071 -
04 view
details		 RECHARGE BATTERIES ON DURING OFF-PEAK DEMAND PERIODS 2.3132 I $ 0 $ 10,469 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 708 kW $ 9,629 $ 13.60 /kW

TOTAL ENERGY

 0 MMBtu $ 9,629 -

Personnel Changes

 - $ 840 -

TOTAL PRODUCTON

 - $ 840 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 40,964 $ 8,693 4.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 141,186 kWh $ 5,619 $ 0.040 /kWh

- Demand Charge

 226 kW $ 3,074 $ 13.60 /kW

TOTAL ENERGY

 1,447 MMBtu $ 8,693 -
06 view
details		 MINIMIZE USE OF OUTSIDE MAKE-UP AIR FOR VENTILATION EXCEPT WHEN USED FOR ECONOMIZER CYCLE 2.7312 I $ 415 $ 8,421 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 957 MMBtu $ 8,421 $ 8.80 /MMBtu

TOTAL ENERGY

 957 MMBtu $ 8,421 -
07 view
details		 STANDARDIZE MOTOR INVENTORY 2.4155 N $ 920 $ 8,227 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 155,965 kWh $ 6,507 $ 0.040 /kWh

- Demand Charge

 250 kW $ 3,400 $ 13.60 /kW

TOTAL ENERGY

 1,599 MMBtu $ 9,907 -

Personnel Changes

 - $ -1,680 -

TOTAL PRODUCTON

 - $ -1,680 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 8,880 $ 4,321 2.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 65,859 kWh $ 2,621 $ 0.040 /kWh

- Demand Charge

 125 kW $ 1,700 $ 13.60 /kW

TOTAL ENERGY

 675 MMBtu $ 4,321 -
09 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 4,975 $ 4,036 1.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 101,417 kWh $ 4,036 $ 0.040 /kWh

TOTAL ENERGY

 1,040 MMBtu $ 4,036 -
10 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 4,181 $ 3,234 1.29
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 52,409 kWh $ 2,089 $ 0.040 /kWh

- Demand Charge

 84 kW $ 1,145 $ 13.60 /kW

TOTAL ENERGY

 537 MMBtu $ 3,234 -
11 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 N $ 2,741 $ 2,929 0.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 46,796 kWh $ 1,862 $ 0.040 /kWh

- Demand Charge

 78 kW $ 1,067 $ 13.60 /kW

TOTAL ENERGY

 480 MMBtu $ 2,929 -
12 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 105 $ 1,961 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,841 kWh $ 1,267 $ 0.040 /kWh

- Demand Charge

 51 kW $ 694 $ 13.60 /kW

TOTAL ENERGY

 326 MMBtu $ 1,961 -
13 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 2,745 $ 1,693 1.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 27,514 kWh $ 1,095 $ 0.040 /kWh

- Demand Charge

 44 kW $ 598 $ 13.60 /kW

TOTAL ENERGY

 282 MMBtu $ 1,693 -
14 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 543 $ 1,412 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,847 kWh $ 909 $ 0.040 /kWh

- Demand Charge

 37 kW $ 503 $ 13.60 /kW

TOTAL ENERGY

 234 MMBtu $ 1,412 -
15 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 423 $ 188 2.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,727 kWh $ 188 $ 0.040 /kWh

TOTAL ENERGY

 48 MMBtu $ 188 -
16 view
details		 REMOVE OR CLOSE OFF UNNEEDED COMPRESSED AIR LINES 2.4235 N $ 555 $ 174 3.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,366 kWh $ 174 $ 0.040 /kWh

TOTAL ENERGY

 45 MMBtu $ 174 -