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IAC Assessment: BD0246
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IAC Assessment: BD0246
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IAC Center Bradley University
Assessment Year 2003
Principal Product Extruded Rollstock and Thermoformed Containers
NAICS 325991 - Custom Compounding of Purchased Resins
SIC 3087 - Custom Compound Purchased Resins
Sales $10,000,000-$50,000,000
# of Employees 104
Plant Area (Sq.Ft.) 145,000
Annual Production 50,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) IN
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $218,417 19,455,864 kWh $0.01
Electricity Demand $569,386 35,370 kW-months/year $16.10
Natural Gas $11,611 1,602 MMBtu $7.25
TOTAL ENERGY COSTS $805,825
RECOMMENDED SAVINGS* $490,559 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $57,883
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Solid Waste (non-haz) Personnel Changes Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Solid Waste (non-haz) Personnel Changes Ancillary Material Cost
$ kWh $ kW-months/year $ MMBtu $ gal $ lb $ $ $ $
01: 2.4224 UPGRADE CONTROLS ON COMPRESSORS Savings:
$24,786
Cost:
$15,000
$4,357 389,059 $20,429 1,269 - - - - - - - - - - $4,357
389,059
kWh
$20,429
1,269
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
02: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$9,982
Cost:
$31,690
$4,028 359,412 $5,954 370 - - - - - - - - - - $4,028
359,412
kWh
$5,954
370
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
03: 2.7124 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED Savings:
$7,990
Cost:
$15,285
$2,814 251,264 $3,302 205 - - - - - - $1,874 - - - $2,814
251,264
kWh
$3,302
205
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
$1,874
-
$
-
-
$
04: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$7,890
Cost:
$200
$2,657 237,219 $5,233 325 - - - - - - - - - - $2,657
237,219
kWh
$5,233
325
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
05: 2.2443 RE-USE OR RECYCLE HOT OR COLD PROCESS EXHAUST AIR Savings:
$5,102
Cost:
$3,000
- - - - $5,102 723 - - - - - - - - -
-
kWh
-
-
kW-months/year
$5,102
723
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
06: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$5,063
Cost:
$1,000
$1,705 152,297 $3,358 209 - - - - - - - - - - $1,705
152,297
kWh
$3,358
209
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
07: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$4,552
Cost:
-
$1,533 136,899 $3,019 188 - - - - - - - - - - $1,533
136,899
kWh
$3,019
188
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
08: 2.7144 INSTALL SPECTRAL REFLECTORS / DELAMP Savings:
$4,085
Cost:
$600
$745 66,466 $1,464 91 - - - - - - $378 - $1,498 - $745
66,466
kWh
$1,464
91
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
$378
-
$
$1,498
-
$
09: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$4,013
Cost:
$4,200
$1,220 108,898 $2,793 174 - - - - - - - - - - $1,220
108,898
kWh
$2,793
174
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
10: 2.2511 INSULATE BARE EQUIPMENT Savings:
$3,886
Cost:
$290
$3,886 95,281 - - - - - - - - - - - - $3,886
95,281
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
11: 2.7231 USE RADIANT HEATER FOR SPOT HEATING Savings:
$2,694
Cost:
$3,000
- - - - $2,694 382 - - - - - - - - -
-
kWh
-
-
kW-months/year
$2,694
382
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
12: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$1,724
Cost:
$500
$580 51,821 $1,144 71 - - - - - - - - - - $580
51,821
kWh
$1,144
71
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
13: 2.4314 USE SYNTHETIC LUBRICANT Savings:
$935
Cost:
$500
$315 28,113 $620 39 - - - - - - - - - - $315
28,113
kWh
$620
39
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
14: 2.7134 USE PHOTOCELL CONTROLS Savings:
$519
Cost:
$500
$75 6,716 $444 28 - - - - - - - - - - $75
6,716
kWh
$444
28
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
15: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$249
Cost:
$322
$37 3,329 $74 5 - - - - - - $58 - $80 - $37
3,329
kWh
$74
5
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
$58
-
$
$80
-
$
16: 3.5212 REGRIND, REUSE, OR SELL SCRAP PLASTIC PARTS Savings:
$36,500
Cost:
$1,000
- - - - - - - - $36,500 1,825,000 - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
$36,500
1,825,000
lb
-
-
$
-
-
$
17: 3.4151 MINIMIZE WATER USAGE Savings:
$841
Cost:
$1,150
- - - - - - $841 219,000 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$841
219,000
gal
-
-
lb
-
-
$
-
-
$
18: 3.5316 CONTRACT A WOOD PALLET RECYCLING COMPANY Savings:
$760
Cost:
$288
- - - - - - - - $760 39,000 - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
$760
39,000
lb
-
-
$
-
-
$
19: 4.4410 INSTALL AUTOMATIC PACKING EQUIPMENT Savings:
$357,438
Cost:
$90,000
- - - - - - - - - - $357,438 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
$357,438
-
$
-
-
$
20: 4.2130 PURCHASE MATERIAL FROM SUPPLIER IN CUSTOMIZED PACKAGING Savings:
$11,550
Cost:
$1,000
- - - - - - - - - - - - $11,550 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
$11,550
-
$
TOTAL RECOMMENDED Savings:
$490,559
Cost:
$169,525
$23,952 1,886,774 $47,834 2,974 $7,796 1,105 $841 219,000 $37,260 1,864,000 $359,748 - $13,128 - $23,952
1,886,774
kWh
$47,834
2,974
kW-months/year
$7,796
1,105
MMBtu
$841
219,000
gal
$37,260
1,864,000
lb
$359,748
-
$
$13,128
-
$
TOTAL IMPLEMENTED Savings:
$57,883
Cost:
$48,680
$18,746 1,421,988 $39,137 2,432 - - - - - - - - - - $18,746
1,421,988
kWh
$39,137
2,432
kW-months/year
-
-
MMBtu
-
-
gal
-
-
lb
-
-
$
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ gal $ lb $ $ $ $
Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Solid Waste (non-haz) Personnel Changes Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Solid Waste (non-haz) Personnel Changes Ancillary Material Cost