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IAC logo
IAC Assessment: NC0322
Sponsored by:
EERE AMO
IAC logo
IAC Assessment: NC0322
IAC Center North Carolina State
Assessment Year 2005
Principal Product Interior packaging materials
NAICS 322211 - Corrugated and Solid Fiber Box Manufacturing
SIC 2671 - Paper Coated & Laminated, Packaging
Sales $10,000,000-$50,000,000
# of Employees 60
Plant Area (Sq.Ft.) 125,000
Annual Production 12,500,000 Pounds
Production Hrs. Annual 4,000
Location (State) VA
View Case Study
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $47,002 1,498,400 kWh $0.03
Electricity Demand $33,836 5,166 kW-months/year $6.55
Electricity Fees $180 - $ -
Natural Gas $85,623 8,089 MMBtu $10.59
TOTAL ENERGY COSTS $166,641
RECOMMENDED SAVINGS* $226,329 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $152,320
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas LPG Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas LPG Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost
$ kWh $ kW-months/year $ MMBtu $ MMBtu $ $ $ $ $ $ $ $
01: 4.4310 TRAIN OPERATORS FOR MAXIMUM OPERATING EFFICIENCY Savings:
$139,400
Cost:
$9,500
- - - - - - - - $14,400 - - - $125,000 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
$14,400
-
$
-
-
$
$125,000
-
$
-
-
$
02: 4.3220 ELIMINATE OLD STOCK AND MODIFY INVENTORY CONTROL Savings:
$8,353
Cost:
$2,650
$243 5,608 $165 17 - - $5,445 363 - - - - $2,500 - - - $243
5,608
kWh
$165
17
kW-months/year
-
-
MMBtu
$5,445
363
MMBtu
-
-
$
-
-
$
$2,500
-
$
-
-
$
03: 4.1110 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK Savings:
$74,009
Cost:
$100,000
$4,328 100,000 $5,700 600 $1,481 140 - - - - $62,500 - - - - - $4,328
100,000
kWh
$5,700
600
kW-months/year
$1,481
140
MMBtu
-
-
MMBtu
-
-
$
$62,500
-
$
-
-
$
-
-
$
04: 2.4151 DEVELOP A REPAIR/REPLACE POLICY Savings:
$573
Cost:
-
$309 7,152 $264 28 - - - - - - - - - - - - $309
7,152
kWh
$264
28
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
$
-
-
$
-
-
$
-
-
$
05: 2.2122 INSTALL / REPAIR INSULATION ON CONDENSATE LINES Savings:
$2,592
Cost:
$821
- - - - $2,592 324 - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$2,592
324
MMBtu
-
-
MMBtu
-
-
$
-
-
$
-
-
$
-
-
$
06: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$462
Cost:
$100
$640 14,800 $422 44 - - - - $(-300) - - - - - $(-300) - $640
14,800
kWh
$422
44
kW-months/year
-
-
MMBtu
-
-
MMBtu
$(-300)
-
$
-
-
$
-
-
$
$(-300)
-
$
07: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$723
Cost:
$298
$436 10,080 $287 30 - - - - - - - - - - - - $436
10,080
kWh
$287
30
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
$
-
-
$
-
-
$
-
-
$
08: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$217
Cost:
$2,000
$131 3,017 $86 9 - - - - - - - - - - - - $131
3,017
kWh
$86
9
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
$
-
-
$
-
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$226,329
Cost:
$115,369
$6,087 140,657 $6,924 728 $4,073 464 $5,445 363 $14,100 - $62,500 - $127,500 - $(-300) - $6,087
140,657
kWh
$6,924
728
kW-months/year
$4,073
464
MMBtu
$5,445
363
MMBtu
$14,100
-
$
$62,500
-
$
$127,500
-
$
$(-300)
-
$
TOTAL IMPLEMENTED Savings:
$152,320
Cost:
$15,369
$1,759 40,657 $1,224 128 $2,592 324 $5,445 363 $14,100 - - - $127,500 - $(-300) - $1,759
40,657
kWh
$1,224
128
kW-months/year
$2,592
324
MMBtu
$5,445
363
MMBtu
$14,100
-
$
-
-
$
$127,500
-
$
$(-300)
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ MMBtu $ $ $ $ $ $ $ $
Electricity Usage Electricity Demand Natural Gas LPG Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas LPG Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost