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IAC Assessment: BD0272
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IAC Assessment: BD0272
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IAC Center Bradley University
Assessment Year 2004
Principal Product Tractor Frames and Assorted Components
NAICS 332999 - All Other Miscellaneous Fabricated Metal Product Manufacturing
SIC 3499 - Fabricated Metal Products, Nec
Sales $50,000,000-$100,000,000
# of Employees 702
Plant Area (Sq.Ft.) 270,000
Annual Production 4,619,925 Pieces
Production Hrs. Annual 8,760
Location (State) IL
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $300,099 10,763,924 kWh $0.03
Electricity Demand $194,457 21,820 kW-months/year $8.91
Electricity Fees $19,263 - $ -
Natural Gas $223,501 32,150 MMBtu $6.95
TOTAL ENERGY COSTS $786,942
RECOMMENDED SAVINGS* $339,453 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $290,570
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Ancillary Material Cost
$ kWh $ kW-months/year $ MMBtu $ Tgal $ lb $ $ $ $ $ $
01: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$42,617
Cost:
$1,000
- - - - $42,617 6,132 - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$42,617
6,132
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
02: 2.7231 USE RADIANT HEATER FOR SPOT HEATING Savings:
$22,780
Cost:
$43,400
- - - - $22,780 3,308 - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$22,780
3,308
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
03: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$18,914
Cost:
$1,000
- - - - $18,914 2,721 - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$18,914
2,721
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
04: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$13,459
Cost:
$1,260
- - - - $13,459 1,937 - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$13,459
1,937
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
05: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$7,568
Cost:
$4,325
$5,265 188,697 $2,303 259 - - - - - - - - - - - - $5,265
188,697
kWh
$2,303
259
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
06: 2.2531 RE-SIZE CHARGING OPENINGS OR ADD MOVABLE COVER OR DOOR Savings:
$5,880
Cost:
$20,000
- - - - $1,966 286 - - - - $3,914 - - - - - -
-
kWh
-
-
kW-months/year
$1,966
286
MMBtu
-
-
Tgal
-
-
lb
$3,914
-
$
-
-
$
-
-
$
07: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$5,875
Cost:
$1,700
$4,086 146,499 $1,789 201 - - - - - - - - - - - - $4,086
146,499
kWh
$1,789
201
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
08: 2.7134 USE PHOTOCELL CONTROLS Savings:
$3,196
Cost:
$2,500
$978 35,040 $642 72 - - - - - - $87 - - - $1,489 - $978
35,040
kWh
$642
72
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$87
-
$
-
-
$
$1,489
-
$
09: 2.2515 USE OPTIMUM THICKNESS INSULATION Savings:
$1,383
Cost:
$1,520
$371 12,658 - - $1,012 146 - - - - - - - - - - $371
12,658
kWh
-
-
kW-months/year
$1,012
146
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
10: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$784
Cost:
$1,500
$199 7,170 $585 66 - - - - - - - - - - - - $199
7,170
kWh
$585
66
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
11: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$448
Cost:
$650
- - - - $448 65 - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$448
65
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
12: 3.5315 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER Savings:
$36,771
Cost:
$7,140
- - - - - - - - $36,771 42,000 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
$36,771
42,000
lb
-
-
$
-
-
$
-
-
$
13: 3.5316 CONTRACT A WOOD PALLET RECYCLING COMPANY Savings:
$16,640
Cost:
$140
- - - - - - - - $16,640 40,800 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
$16,640
40,800
lb
-
-
$
-
-
$
-
-
$
14: 3.4111 USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION Savings:
$14,414
Cost:
$590
- - - - - - $14,414 3,276,000 - - - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$14,414
3,276,000
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
15: 3.1163 USE PLASTIC PALLETS INSTEAD OF WOOD Savings:
$11,370
Cost:
$9,000
- - - - - - - - $11,370 20,400 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
$11,370
20,400
lb
-
-
$
-
-
$
-
-
$
16: 4.422 UTILIZE OUTSIDE CONTRACTING Savings:
$57,614
Cost:
$200
- - - - - - - - - - - - $57,614 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
$57,614
-
$
-
-
$
17: 4.513 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE LABOR COSTS Savings:
$59,000
Cost:
$15,000
- - - - - - - - - - - - $59,000 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
$59,000
-
$
-
-
$
18: 4.821 PAY BILLS ON TIME TO AVOID LATE FEES Savings:
$20,740
Cost:
-
- - - - - - - - - - - - $20,740 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
$20,740
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$339,453
Cost:
$110,925
$10,899 390,064 $5,319 597 $101,196 14,594 $14,414 3,276,000 $64,781 103,200 $4,001 - $137,354 - $1,489 - $10,899
390,064
kWh
$5,319
597
kW-months/year
$101,196
14,594
MMBtu
$14,414
3,276,000
Tgal
$64,781
103,200
lb
$4,001
-
$
$137,354
-
$
$1,489
-
$
TOTAL IMPLEMENTED Savings:
$290,570
Cost:
$62,005
$9,351 335,196 $4,092 459 $77,404 11,140 $14,414 3,276,000 $64,781 103,200 $3,914 - $116,614 - - - $9,351
335,196
kWh
$4,092
459
kW-months/year
$77,404
11,140
MMBtu
$14,414
3,276,000
Tgal
$64,781
103,200
lb
$3,914
-
$
$116,614
-
$
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ Tgal $ lb $ $ $ $ $ $
Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Ancillary Material Cost