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

Industrial Assessment Centers

Assessment #WV0446


Assessment Year 2012
SIC 2087
SIC Description Flavoring Extracts And Syrups, Nec
NAICS 311930
NAICS Description Flavoring Syrup and Concentrate Manufacturing
Principal Product Flavors
Sales $ 100,000,000
# of Employees 200
Plant Area (Sq.Ft.) 110,000
Annual Production 10,000,000 Pounds
Production Hrs. Annual 8,568
Location (State) MD
Yearly Energy Cost $ 1,384,978

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,659,300 kWh $ 924,720 $ 0.096 /kWh

- Demand Charge

 19,071 kW $ 45,961 $ 2.41 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 59,431 MMBtu $ 414,297 $ 6.97 /MMBtu

TOTAL ENERGY

 158,440 MMBtu $ 1,384,978 $ 8.74 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,026,333 kWh
324,517 kWh		 $ 289,676
$ 31,067		 31.33 %
3.36 %		 $ 0.096 /kWh

- Demand Charge

 4,939 kW
454 kW		 $ 11,903
$ 1,094		 25.90 %
2.38 %		 $ 2.41 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -3,966 MMBtu
1,614 MMBtu		 $ -27,642
$ 11,250		 -6.67 %
2.72 %		 $ 6.97 /MMBtu

TOTAL ENERGY

 27,054 MMBtu
4,940 MMBtu		 $ 273,937
$ 43,411		 19.78 %
3.13 %		 $ 8.74 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 BURN FOSSIL FUEL TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR AND USE STEAM EXHAUST FOR HEAT 2.3413 N $ 548,000 $ 147,469 3.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,090,952 kWh $ 200,132 $ 0.096 /kWh

- Demand Charge

 2,928 kW $ 7,056 $ 2.41 /kW

Natural Gas

 -8,568 MMBtu $ -59,719 $ 6.97 /MMBtu

TOTAL ENERGY

 12,864 MMBtu $ 147,469 -
02 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 70,000 $ 21,144 3.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 213,343 kWh $ 20,423 $ 0.096 /kWh

- Demand Charge

 299 kW $ 721 $ 2.41 /kW

TOTAL ENERGY

 2,187 MMBtu $ 21,144 -
03 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 21,000 $ 20,208 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 211,098 kWh $ 20,208 $ 0.096 /kWh

TOTAL ENERGY

 2,164 MMBtu $ 20,208 -
04 view
details		 ESTABLISH A PREVENTATIVE MAINTENANCE PROGRAM 2.4156 I $ 1,000 $ 16,273 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 173,369 kWh $ 16,597 $ 0.096 /kWh

- Demand Charge

 243 kW $ 586 $ 2.41 /kW

TOTAL ENERGY

 1,777 MMBtu $ 17,183 -

Personnel Changes

 - $ -910 -

TOTAL PRODUCTON

 - $ -910 -
05 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 N $ 2,034 $ 10,748 0.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 108,450 kWh $ 10,382 $ 0.096 /kWh

- Demand Charge

 152 kW $ 366 $ 2.41 /kW

TOTAL ENERGY

 1,112 MMBtu $ 10,748 -
06 view
details		 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES 2.1221 N $ 9,500 $ 9,842 0.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,412 MMBtu $ 9,842 $ 6.97 /MMBtu

TOTAL ENERGY

 1,412 MMBtu $ 9,842 -
07 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 32,125 $ 8,197 3.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,176 MMBtu $ 8,197 $ 6.97 /MMBtu

TOTAL ENERGY

 1,176 MMBtu $ 8,197 -
08 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 2,500 $ 6,963 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,014 MMBtu $ 7,068 $ 6.97 /MMBtu

TOTAL ENERGY

 1,014 MMBtu $ 7,068 -

Personnel Changes

 - $ -105 -

TOTAL PRODUCTON

 - $ -105 -
09 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 5,683 $ 6,712 0.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 88,907 kWh $ 8,511 $ 0.096 /kWh

- Demand Charge

 125 kW $ 301 $ 2.41 /kW

TOTAL ENERGY

 911 MMBtu $ 8,812 -

Personnel Changes

 - $ -2,100 -

TOTAL PRODUCTON

 - $ -2,100 -
10 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 423 $ 6,393 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 64,517 kWh $ 6,176 $ 0.096 /kWh

- Demand Charge

 90 kW $ 217 $ 2.41 /kW

TOTAL ENERGY

 661 MMBtu $ 6,393 -
11 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 I $ 4,438 $ 3,610 1.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 600 MMBtu $ 4,182 $ 6.97 /MMBtu

TOTAL ENERGY

 600 MMBtu $ 4,182 -

Personnel Changes

 - $ -572 -

TOTAL PRODUCTON

 - $ -572 -
12 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 1,070 $ 2,862 0.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,893 kWh $ 2,766 $ 0.096 /kWh

- Demand Charge

 40 kW $ 96 $ 2.41 /kW

TOTAL ENERGY

 296 MMBtu $ 2,862 -
13 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 N $ 1,351 $ 2,788 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 400 MMBtu $ 2,788 $ 6.97 /MMBtu

TOTAL ENERGY

 400 MMBtu $ 2,788 -
14 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 N $ 5,700 $ 2,403 2.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 997 kW $ 2,403 $ 2.41 /kW

TOTAL ENERGY

 0 MMBtu $ 2,403 -
15 view
details		 CHILL WATER TO THE HIGHEST TEMPERATURE POSSIBLE 2.2625 I $ 70 $ 2,151 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,715 kWh $ 2,079 $ 0.096 /kWh

- Demand Charge

 30 kW $ 72 $ 2.41 /kW

TOTAL ENERGY

 223 MMBtu $ 2,151 -
16 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,625 $ 1,334 1.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,456 kWh $ 1,288 $ 0.096 /kWh

- Demand Charge

 19 kW $ 46 $ 2.41 /kW

TOTAL ENERGY

 138 MMBtu $ 1,334 -
17 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 475 $ 1,153 0.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,633 kWh $ 1,114 $ 0.096 /kWh

- Demand Charge

 16 kW $ 39 $ 2.41 /kW

TOTAL ENERGY

 119 MMBtu $ 1,153 -