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IAC Assessment: BD0255
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IAC Assessment: BD0255
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IAC Center Bradley University
Assessment Year 2004
Principal Product Industrial Coatings
NAICS 325510 - Paint and Coating Manufacturing
SIC 2851 - Paints And Allied Products
Sales $10,000,000-$50,000,000
# of Employees 100
Plant Area (Sq.Ft.) 60,000
Annual Production 23,000,000 Pounds
Production Hrs. Annual 6,240
Location (State) IL
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $207,689 3,738,240 kWh $0.06
Electricity Demand $82,852 8,210 kW-months/year $10.09
Natural Gas $71,679 11,712 MMBtu $6.12
TOTAL ENERGY COSTS $365,994
RECOMMENDED SAVINGS* $84,303 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* -
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes Primary Raw Material Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes Primary Raw Material
$ kWh $ kW-months/year $ MMBtu $ $ $ $ $ $
01: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$16,352
Cost:
$17,885
$10,814 380,765 $5,538 549 - - - - - - - - $10,814
380,765
kWh
$5,538
549
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
02: 2.7495 INSTALL REPLACEMENT DOORS Savings:
$13,961
Cost:
$14,000
- - - - $821 140 $13,140 - - - - - -
-
kWh
-
-
kW-months/year
$821
140
MMBtu
$13,140
-
$
-
-
$
-
-
$
03: 4.1110 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK Savings:
$11,914
Cost:
$11,000
$8,450 297,550 $3,464 343 - - - - - - - - $8,450
297,550
kWh
$3,464
343
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
04: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$7,576
Cost:
$13,050
$4,501 158,480 $3,075 305 - - - - - - - - $4,501
158,480
kWh
$3,075
305
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
05: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$3,780
Cost:
$2,000
$2,539 89,414 $1,241 123 - - - - - - - - $2,539
89,414
kWh
$1,241
123
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
06: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$2,761
Cost:
$2,550
$1,045 36,730 $1,525 151 - - $35 - - - $156 - $1,045
36,730
kWh
$1,525
151
kW-months/year
-
-
MMBtu
$35
-
$
-
-
$
$156
-
$
07: 2.1213 DIRECT WARMEST AIR TO COMBUSTION INTAKE Savings:
$2,586
Cost:
$2,000
- - - - $2,586 444 - - - - - - -
-
kWh
-
-
kW-months/year
$2,586
444
MMBtu
-
-
$
-
-
$
-
-
$
08: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$1,238
Cost:
$750
$834 29,738 $404 40 - - - - - - - - $834
29,738
kWh
$404
40
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
09: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$1,069
Cost:
$1,500
- - - - $1,069 183 - - - - - - -
-
kWh
-
-
kW-months/year
$1,069
183
MMBtu
-
-
$
-
-
$
-
-
$
10: 2.1222 INSTALL TURBULATORS Savings:
$899
Cost:
$1,200
- - - - $899 153 - - - - - - -
-
kWh
-
-
kW-months/year
$899
153
MMBtu
-
-
$
-
-
$
-
-
$
11: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$739
Cost:
$995
$236 8,299 $160 16 - - $144 - - - $199 - $236
8,299
kWh
$160
16
kW-months/year
-
-
MMBtu
$144
-
$
-
-
$
$199
-
$
12: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$570
Cost:
$150
$318 11,190 $252 25 - - - - - - - - $318
11,190
kWh
$252
25
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
13: 2.3131 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS Savings:
$12,428
Cost:
$2,000
- - $12,428 1,232 - - - - - - - - -
-
kWh
$12,428
1,232
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
14: 4.4470 AUTOMATE PAYROLL SYSTEM Savings:
$6,240
Cost:
$3,000
- - - - - - $6,240 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$6,240
-
$
-
-
$
-
-
$
15: 4.8210 PAY BILLS ON TIME TO AVOID LATE FEES Savings:
$2,190
Cost:
-
- - - - - - - - $2,190 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
$2,190
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$84,303
Cost:
$72,080
$28,737 1,012,166 $28,087 2,784 $5,375 920 $19,559 - $2,190 - $355 - $28,737
1,012,166
kWh
$28,087
2,784
kW-months/year
$5,375
920
MMBtu
$19,559
-
$
$2,190
-
$
$355
-
$
TOTAL IMPLEMENTED Savings:
-
Cost:
-
- - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $ $ $ $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes Primary Raw Material Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes Primary Raw Material