An energy survey was conducted for this moderate size (162,000 square foot) plant dedicated to the production of parts for the automotive industry. With a peak electrical demand of approximately 2,300 kW and annual energy consumption of 16.7 million kWh, this plant had recently completed an energy management effort focused on the production processes. This survey emphasized selected utilities and end use applications, in an effort to further reduce energy expenditures.

Areas of Investigation:

The specific areas of emphasis for this survey were limited to the compressed air systems, AC electric motors, interior/exterior lighting systems and an electrical rate analysis.

Survey Results/Savings Potential:

As a result of this survey, recommendations were provided for potential annual energy saving of $28,300, with a collective average simple payback of less than one year. This equated to an annual electrical expenditure reduction of approximately 4.2%.

Recommendations were also provided regarding maintenance and establishment of policies that would ensure continued efficient operation, with emphasis on safety and the environment.

Environmental Impact:

The recommended measures in this survey have the potential of reducing the amount of CO₂ discharged into the atmosphere by 2.6 million pounds annually. In addition, these measures can reduce the emission levels of SO₂ by 16,630 lbs. and NOx by 6,475 lbs. each year.

A summary of the recommended measures and their estimated annual savings is presented in the following table.

Table – Recommended Measures Case Study No.3