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IAC Assessment: KU0511
Sponsored by:
DOE MESC
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IAC Assessment: KU0511
IAC Center Univ. of Kansas
Assessment Year 1998
Principal Product hand tools
NAICS n/a
SIC 3423 - Hand And Edge Tools, Nec
Sales $10,000,000-$50,000,000
# of Employees 250
Plant Area (Sq.Ft.) 126,675
Annual Production 4,500,000 Pieces
Production Hrs. Annual 6,000
Location (State) NE
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $153,143 7,856,389 kWh $0.02
Electricity Demand $159,650 18,142 kW-months/year $8.80
Natural Gas $70,927 13,494 MMBtu $5.26
TOTAL ENERGY COSTS $572,230
RECOMMENDED SAVINGS* $163,690 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $61,990
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Personnel Changes Ancillary Material Cost Primary Product Electricity Usage Electricity Demand Natural Gas Personnel Changes Ancillary Material Cost Primary Product
$ kWh $ kW-months/year $ MMBtu $ $ $ $ $ $
01: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$25,680
Cost:
$19,610
- - - - $25,680 4,900 - - - - - - -
-
kWh
-
-
kW-months/year
$25,680
4,900
MMBtu
-
-
$
-
-
$
-
-
$
02: 2.1311 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT Savings:
$8,600
Cost:
$32,720
$17,690 907,093 $11,180 1,270 $(-20,270) (-3,869) - - - - - - $17,690
907,093
kWh
$11,180
1,270
kW-months/year
$(-20,270)
(-3,869)
MMBtu
-
-
$
-
-
$
-
-
$
03: 2.2523 REDUCE INFILTRATION TO REFRIGERATED AREAS; ISOLATE HOT EQUIPMENT FROM REFRIGERATED AREAS Savings:
$3,080
Cost:
$3,040
$1,920 98,183 $1,160 132 - - - - - - - - $1,920
98,183
kWh
$1,160
132
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
04: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$2,570
Cost:
$2,550
- - - - $2,570 491 - - - - - - -
-
kWh
-
-
kW-months/year
$2,570
491
MMBtu
-
-
$
-
-
$
-
-
$
05: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$2,560
Cost:
$800
$1,350 68,875 $1,210 138 - - - - - - - - $1,350
68,875
kWh
$1,210
138
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
06: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$1,670
Cost:
$3,960
$560 28,429 $470 53 - - $640 - - - - - $560
28,429
kWh
$470
53
kW-months/year
-
-
MMBtu
$640
-
$
-
-
$
-
-
$
07: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$590
Cost:
$360
$310 15,826 $280 32 - - - - - - - - $310
15,826
kWh
$280
32
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
-
-
$
08: 2.2511 INSULATE BARE EQUIPMENT Savings:
$230
Cost:
$680
$30 1,465 $50 6 $150 28 - - - - - - $30
1,465
kWh
$50
6
kW-months/year
$150
28
MMBtu
-
-
$
-
-
$
-
-
$
09: 4.4540 MODIFY STARTUP/SHUTDOWN TIMES Savings:
$75,530
Cost:
-
- - - - - - - - - - $75,530 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
$75,530
-
$
10: 4.1110 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK Savings:
$15,070
Cost:
$17,000
- - - - - - - - - - $15,070 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
$15,070
-
$
11: 4.4460 AUTOMATE FINISHING PROCESS Savings:
$12,150
Cost:
$42,810
- - - - - - $12,150 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$12,150
-
$
-
-
$
-
-
$
12: 4.1110 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK Savings:
$5,560
Cost:
$690
- - - - - - $6,080 - $(-520) - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$6,080
-
$
$(-520)
-
$
-
-
$
13: 4.1310 MODIFY PROCESS TO REDUCE MATERIAL USE/COST Savings:
$4,980
Cost:
$10,000
- - - - - - - - $4,980 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
$4,980
-
$
-
-
$
14: 4.6110 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE Savings:
$4,120
Cost:
$4,400
$710 36,342 $480 55 - - $(-39,160) - - - $42,090 - $710
36,342
kWh
$480
55
kW-months/year
-
-
MMBtu
$(-39,160)
-
$
-
-
$
$42,090
-
$
15: 4.2220 PURCHASE RE-CONDITIONED MATERIAL INSTEAD OF NEW Savings:
$1,300
Cost:
$800
- - - - - - $1,420 - $(-120) - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$1,420
-
$
$(-120)
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$163,690
Cost:
$139,420
$22,570 1,156,213 $14,830 1,686 $8,130 1,550 $(-18,870) - $4,340 - $132,690 - $22,570
1,156,213
kWh
$14,830
1,686
kW-months/year
$8,130
1,550
MMBtu
$(-18,870)
-
$
$4,340
-
$
$132,690
-
$
TOTAL IMPLEMENTED Savings:
$61,990
Cost:
$58,690
$4,170 212,778 $3,170 361 $28,400 5,419 $6,720 - $4,460 - $15,070 - $4,170
212,778
kWh
$3,170
361
kW-months/year
$28,400
5,419
MMBtu
$6,720
-
$
$4,460
-
$
$15,070
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $ $ $ $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Ancillary Material Cost Primary Product Electricity Usage Electricity Demand Natural Gas Personnel Changes Ancillary Material Cost Primary Product