IAC logo
IAC Assessment: LE0317
Sponsored by:
DOE MESC
IAC logo
IAC Assessment: LE0317
IAC Center Lehigh University
Assessment Year 2011
Principal Product Vinyl Film
NAICS 326113 - Unlaminated Plastics Film and Sheet (except Packaging) Manufacturing
SIC 3083 - Laminated Plastics Plate & Sheet
Sales $10,000,000-$50,000,000
# of Employees 46
Plant Area (Sq.Ft.) 180,000
Annual Production 63,000 Thousand Feet
Production Hrs. Annual 6,000
Location (State) PA
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $737,130 14,397,600 kWh $0.05
Electricity Demand $264,643 30,770 kW-months/year $8.60
Natural Gas $948,636 103,342 MMBtu $9.18
TOTAL ENERGY COSTS $1,950,409
RECOMMENDED SAVINGS* $668,178 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $605,353
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Personnel Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes
$ kWh $ kW-months/year $ MMBtu $ $
01: 2.1224 REPLACE BOILER Savings:
$284,580
Cost:
$500,000
- - - - $284,580 31,000 - - -
-
kWh
-
-
kW-months/year
$284,580
31,000
MMBtu
-
-
$
02: 2.2449 RECOVER HEAT FROM EXHAUSTED STEAM, HOT AIR OR HOT WATER Savings:
$185,253
Cost:
$118,000
- - - - $185,253 20,180 - - -
-
kWh
-
-
kW-months/year
$185,253
20,180
MMBtu
-
-
$
03: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$57,617
Cost:
$13,469
$44,786 878,173 $12,831 1,492 - - - - $44,786
878,173
kWh
$12,831
1,492
kW-months/year
-
-
MMBtu
-
-
$
04: 2.2692 USE OUTSIDE COLD WATER SOURCE AS A SUPPLY OF COOLING WATER Savings:
$28,496
Cost:
$10,000
$28,496 558,742 - - - - - - $28,496
558,742
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
05: 2.2449 RECOVER HEAT FROM EXHAUSTED STEAM, HOT AIR OR HOT WATER Savings:
$24,299
Cost:
$75,000
- - - - $24,299 2,647 - - -
-
kWh
-
-
kW-months/year
$24,299
2,647
MMBtu
-
-
$
06: 2.2113 REPAIR OR REPLACE STEAM TRAPS Savings:
$23,321
Cost:
$4,200
- - - - $23,321 2,540 - - -
-
kWh
-
-
kW-months/year
$23,321
2,540
MMBtu
-
-
$
07: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$12,721
Cost:
$22,000
- - - - $12,721 1,385 - - -
-
kWh
-
-
kW-months/year
$12,721
1,385
MMBtu
-
-
$
08: 4.652 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES Savings:
$11,375
Cost:
$100,000
$1,354 26,541 $22 3 - - $10,000 - $1,354
26,541
kWh
$22
3
kW-months/year
-
-
MMBtu
$10,000
-
$
09: 4.652 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES Savings:
$8,387
Cost:
$8,000
$6,332 124,153 $2,055 239 - - - - $6,332
124,153
kWh
$2,055
239
kW-months/year
-
-
MMBtu
-
-
$
10: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$8,358
Cost:
$870
$8,358 163,888 - - - - - - $8,358
163,888
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
11: 2.3131 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS Savings:
$7,938
Cost:
$3,000
- - $7,938 923 - - - - -
-
kWh
$7,938
923
kW-months/year
-
-
MMBtu
-
-
$
12: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$6,001
Cost:
$4,500
$4,917 96,419 $1,084 126 - - - - $4,917
96,419
kWh
$1,084
126
kW-months/year
-
-
MMBtu
-
-
$
13: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$4,553
Cost:
$2,440
$3,435 67,371 $1,118 130 - - - - $3,435
67,371
kWh
$1,118
130
kW-months/year
-
-
MMBtu
-
-
$
14: 2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO Savings:
$4,029
Cost:
$20,000
- - - - $4,029 439 - - -
-
kWh
-
-
kW-months/year
$4,029
439
MMBtu
-
-
$
15: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$1,097
Cost:
$2,035
$1,097 21,504 - - - - - - $1,097
21,504
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
16: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$153
Cost:
$1,000
- - - - $153 17 - - -
-
kWh
-
-
kW-months/year
$153
17
MMBtu
-
-
$
TOTAL RECOMMENDED Savings:
$668,178
Cost:
$884,514
$98,775 1,936,791 $25,048 2,913 $534,356 58,208 $10,000 - $98,775
1,936,791
kWh
$25,048
2,913
kW-months/year
$534,356
58,208
MMBtu
$10,000
-
$
TOTAL IMPLEMENTED Savings:
$605,353
Cost:
$775,014
$65,361 1,281,630 $23,964 2,787 $506,028 55,122 $10,000 - $65,361
1,281,630
kWh
$23,964
2,787
kW-months/year
$506,028
55,122
MMBtu
$10,000
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes