BETTER BUILDINGS BY DESIGN CONFERENCE 2008 Designing a Sustainable Commercial Kitchen FEBRUARY 13 BURLINGTON, VERMONT

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3 BETTER BUILDINGS BY DESIGN CONFERENCE 2008 Designing a Sustainable Commercial Kitchen FEBRUARY 13 BURLINGTON, VERMONT Don Fisher Manager PG&E Food Service Technology Center dfisher@fishnick.com Your online toolbox Reports Energy Saving tips Design guides Cost calculators Rebates

4 Role of the Food Service Technology Center Appliance Testing Laboratory create standard test methods and the miles-per-gallon and zero to sixty numbers for appliances

5 ASTM Test Methods for 32 appliance types! The Commercial Kitchen Energy [and Water] Intensive! 5 times more Btu/sq. ft. than other commercial Long Operating hours 14 to 20 hours a day typical (some are 24 h/day) Little or No Planning for Efficiency Low Equipment Turnover appliances are expensive and last 5 to 40 years A Challenging Environment!

6 Let s Take a Quick Kitchen Tour Diversity

7 Down Time Energy Guzzlers

8 No Overhang Where is the exhaust duct?

9 Kettles off Hood on or not enough hood!

10 or more hood than unnecessary! or no hood!

11 or a fake hood! Low-Efficiency Burners

12 Blast chiller always on but not never used The little drip

13 How much is too much? Auto door closer no longer on auto

14 Strip curtains only work if So where does the energy go?

15 Food Prep Strategies Sanitation Lighting 18% 13% Refrig 6% HVAC 28% Food Prep 35% specify energy-efficient equipment control technologies appropriate appliance choices effective startup and shutdown schedules An Energy Perspective = = An appliance energy bill can easily match your gasoline bill!

16 If you had to gas each appliance every morning, your perspective would quickly change at $1.20 per therm! Rated input: 144,000 Btu/hr Average consumption of 100,000 Btu/h Over a 10 hr Day 360 days per $1.20/therm 100,000 Btu/h = 1 therm, so.. 1 therm x 10 hr x 360 days = 3600 therms/yr = 3600 therms x $1.20 = $4320/yr!

17 Appliances are not created equal! What makes an appliance more efficient? Induction Good Heat Exchange Smart Controls Insulation Powered or IR Burners

18 ... less efficient? Poor Heat Exchange Low-Cost Components No Insulation Manual Control Insulation Saves Energy! 40% Reduction in Energy Use

19 The Dilemma... selecting an energy-efficient appliance when little or no performance information is available! Refrigeration Fryers Holding Cabinets Steamers

20 Upcoming Commercial Food Service Products: Dishwashers NAFEM 2007 Ice Machines January 1, 2008 Griddles Convection Ovens Life Cycle Cost The Big Picture

21 Determine the Real Cost! Insulated Energy Star Hot Food Holding Cabinets

22 Life-Cycle Costs* Hot Food Holding Cabinets Purchase Energy $6,000 Present Value $5,000 $4,000 $3,000 $2,000 $1,000 $0 uninsulated cabinet insulated cabinet $2,200! *Based on 10 /kwh, a 5-year life expectancy and a 3.1% discount rate Energy Star Steamer Saves Big on Water and Energy

23 Boiler Based Steamer (Not ENERGY STAR) Average Water Usage = 40 gph 5- Year Life-Cycle Costs Three-Pan Steamer Example Present Value $20,000 $18,000 $16,000 $14,000 $12,000 $10,000 $8,000 $6,000 $4,000 $2,000 $0 Purchase Water Maintenance Energy $11,500! base ENERGY STAR best ENERGY STAR $650

24 High-Efficiency Energy Star Gas Fryer Advantages: faster recovery higher production rate longer lifespan will pay for itself Life-Cycle Cost* vs. Purchase Cost Present Value $18,000 $16,000 $14,000 $12,000 $10,000 $8,000 $6,000 $4,000 $2,000 $0 Purchase Maintenance Energy Base Fryer Energy Star Fryer *Based on $1.20/therm, 16-hr/day usage, 125 lb/day food cooked, a 8-year life expectancy and a 3.1% discount rate $3,195!

25 Dead giveaway for an Inefficient Fryer Cast Iron Burner Sanitation Strategies Sanitation 18% Lighting 13% Refrig 6% high efficiency hot water heater/boiler Energy Star dishwashers gas booster heaters HVAC 28% low flow prerinse spray valves refrigerant heat recovery for DHW preheat waste water heat recovery (someday???) Food Prep 35%

26 The $4000 Leak!

27 Refrigeration Strategies Sanitation 18% Lighting 13% Refrig 6% remote compressors advanced compressors hot gas defrost - smart defrost floating head pressure strip curtains, plastic doors, and auto door closers construction and insulation HVAC 28% high efficiency evaporator fan motors (ECM) Energy Star reach in freezers, refrigerators & ice machines Food Prep 35% Evaporator Fan Motors Install high-efficiency electronically commutated (ECM) motors. Example: Low efficiency motor draws 135 watts ECM motor draws only 44 watts Save 91 watts or $120 dollars a year of fan energy Save $60 to $120 dollars a year of compressor energy Motor costs about $150 Payback is less than one year!

28 Ice Machines Water & Energy Saving Candidates? Ice machines are found in a wide variety of commercial applications: from bars, delis, and restaurants, to hotels, hospitals, and other institutional kitchens. Typically harvest ice from 200 lb/24 hr to 1600 lb/24 hr ARI Ice Machine Database Air-Conditioning & Refrigeration Institute (ARI)* Ice harvest (lb/24 hr) Water usage (gal/100 lb ice) Energy consumption rate (kwh/100 lb ice) Condenser water usage (gal/100 lb ice) *(

29 Restaurant Field Monitoring Case Study 1. Increased ice machine capacity 2. Ice machine on a timer: runs only at night From: To: 194 lb/day 12.2 kwh/100 lb 28.7gal/100 lb 18.6 kwh/day $650/year 570 lb/day 6.5 kwh/100 lb 26.4 gal/100 lb 7.25 kwh/day $ $0.10/kWh

30 From: To: Save $400 a year quieter kitchen cooler kitchen more ice available reduce demand by 1kw Sanitation 18% Lighting 13% Refrig 6% HVAC Strategies evaporative coolers economizers heat recovery effective exhaust hoods & control optimized makeup air HVAC 28% commissioning and rebalancing properly set make-up air duct thermostats Food Prep 35%

31 The Heart of Restaurant HVAC rooftop equipment! let s drop on a few exhaust fans! it doesn t get easier!

32 Why care? $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ $ 3 Billion CFM exhausted from Commercial Kitchens in the U.S.

33 Makeup Air Heating & Cooling Fan Energy Outdoor Air Load Calculator and Fan Energy Estimator Free Download:

34 So how much..is too much?

35 depends on Appliance Category and Usage vs. Depends on Hood Style & Design

36 Wall-Mounted Canopy Proximity (Backshelf) Hood

37 Double-Island Canopy Single-Island Canopy

38 This island style looks ok.. until the broiler is turned on!

39 What is missing? What needs to go?

40 Single-Island Canopy New Guide: Focused on Hood Selection & Sizing Download at:

41 Food Service Technology Center affiliated with the Commercial Kitchen Ventilation Lab Wood Dale, IL Manager: Rich Swierczyna Architectural Energy Corp. Ph: Lab Originally Designed by McDonald s for Optimizing Hood Performance Schlieren Flow Visualization Hood Hood Spillage of Plume at 165cfm/lf Capture and Containment at 220 cfm/lf Range Top (side view) Range Top (side view)

42 What the Eye Sees! 8-Ft Wall Mounted Canopy Hood What the Camera Sees! Hood Does Not Capture & Contain

43 Makeup Air Introduced at Low Velocity Capture & Containment 1400 CFM Hood Setup over Two Charbroilers 8-Foot Wall Mounted Canopy Hood

44 Island Canopy with Displacement MUA (C&C 5100 cfm, 2 charbroilers cooking) Wall Canopy with Displacement MUA (C&C 4100 cfm, 2 charbroilers cooking)

45 Proximity Hood with Displacement MUA (C&C 1250 cfm, 2 charbroilers cooking) If Less Exhaust Saves Money Which Hood Would You Choose? Exhaust Flow Rate [CFM] cfm/ft Two Charbroilers Cooking No Side Panels No Drafts cfm/ft cfm/ft Island-Mounted Canopy Wall-Mounted Canopy Proximity 8 ft hood 8 ft hood 7.2 ft hood

46 Add in an Engineered Wall-Canopy Hood Two 3-Foot Charbroilers Cooking under an 8-Foot Hood 6000 Exhaust Flow Rate (cfm) cfm/ft cfm/ft But this hood was listed for 600ºF at 210 cfm/ft! 213 cfm/ft cfm/ft cfm/ft 0 Standard Single Island Canopy Hood Standard Wall Canopy Hood (with 6 in. overhang) Engineered Wall Canopy Hood (18 in. overhang w/ side panels) Engineered Proximity (Backshelf) Hood Replacement (Makeup) Air Options Transfer air (e.g., from dining room) Displacement diffusers (floor or wall) Ceiling diffusers (2-way, 3-way, 4-way) Slot diffusers (ceiling) Ceiling diffusers with perforated face Integrated hood plenum including

47 Short circuit (internal supply) Air curtain supply Front face supply Perforated perimeter supply Backwall supply (rear discharge) Combinations of the above Short-Circuit Concept

48 Trained arrows say yes! But others say no!

49 Bad concept! The Mechanical Design Disconnect!

50 And hoods are not created equal 4-Way Diffuser Set-up

51 8-Ft Wall Mounted Canopy Hood 1400 SCFM to 4 Way Focused on minimizing the effect that makeup air supply can have on the performance of exhaust hoods

52 What can make a hood work better? 9 times out of 10 it is not more exhaust! partial end panels do the job!

53 What s wrong with this installation? Could This Hood Be Improved?

54 or this one? or this one?

55 or this one? close that gap!

56 and add that side panel! There are hoods everywhere that would benefit from a side panel

57 Tools for the Design Tool Box: Bigger hoods Deeper Taller Push back equipment (maximize overhang, minimize rear gap) Lower hoods (or proximity style where practical) Side panels, end panels, end walls!!!!!! Heavy duty (broiler) in middle Light duty (ovens) on the end Don t waste hood space over non-cooking Introduce makeup air at low velocity. Three Nuggets

58 Push Back (and close gap) Bigger Hood

59 Side Panels A bit more stainless steel can be cheap insurance! Bonus Point! No 4-Way Diffusers Near Hood!

60 Variable Speed Fans Applying Demand Ventilation Control to Commercial Kitchen Ventilation Consider variable speed drives for kitchen exhaust and makeup air fans

61 Problem: The kitchen exhaust hood operates at 100%. All day long. (And sometimes all night as well.) Whether cooking or not! Variable Frequency Drives (VFD) Essentially electronic motor starters that replace magnetic starters Add flexibility to direct drive fans Cornerstone of a DVC system May be considered a separate value proposition from DVC

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63 Energy Management Effectively reduces exhaust and supply airflow rates saving restaurant operators both energy and money Fully modulating digital temperature control Meets IMC requirements by activating exhaust fans when cooking appliances are energized Fully adjustable set-points Case Study: 24/7 Hotel Kitchen

64 Fan Power with and w/o DVC 16 With and Without Melink Exhaust and Makeup Fan Power With Melink DVC5.3 kw W/O Melink DVC 14 kw Avg. Reduction = 8.7 kw :00 AM 1:15 AM 2:30 AM 3:45 AM 5:00 AM 6:15 AM 7:30 AM 8:45 AM 10:00 AM 11:15 AM 12:30 PM 1:45 PM 3:00 PM 4:15 PM 5:30 PM 6:45 PM kw 8:00 PM 9:15 PM 10:30 PM 11:45 PM Time Super Market

65 Power (kw) Without DVC With DVC Combined Exhaust Fans Reduction = 5.1 KW Time College Dining

66 5 4 Rear Exhaust Fan - Typical Day Power Profile Average w/o DVC Fan Power Reduction = 2.2 kw Power (kw) 3 2 Average w/ DVC Time Exhaust Air Heat Recovery in Large Kitchen Ventilation?

67 Air-to-Air Heat Recovery Unit West Point

68 West Point Lighting Strategies Sanitation 18% Lighting 13% Refrig 6% efficient lighting day lighting and dimming HVAC 28% EMS control and occupancy sensors energy management system effective lighting design Food Prep 35%

69 Hidden Applications for Compact Fluorescent Lamps (CFL)

70 In the walk-in refrigerator: Use Low-temp CFLs for freezers. amalgam lamps work best Save $30 a year per lamp! 16 $0.10/kWh Take advantage of CFL flood lamps! 19 watt replaces 75 watt incandescent

71 How much would CFL floods save? $1,700 in energy per year! 75 lamps, 15 hours a $0.10/kWh

72 Track lighting with CFL floods Exterior Lighting

73 GE and Phillips have Dimming CFL Floods Small CFLs for decorative fixtures

74 Small CFLs 4 watts 13 watts 9 watt 4 watts Decorative example: 9 watts 10,000 hour life Cost $6 to $10

75 Cold Cathode CFLs 3 or 5 watts replaces 15 to 20 watts Can be rapidly switched (flashing signs) Dimming 25,000 hour life! $10 to $15

76 Floods and Spots R30 flood light 11 watt LED = 60 watt halogen cool or warm white and CRI = 80 $120 R16 flood light 4.8 watt LED = 20 watt halogen cool or warm white and CRI = 80 $50 LED Decorative ($180) LED fixture = 2 watts incandescent fixture = 40 watts mini - CFL fixture = 9 watts

77 LED Downlight ($210) source: The new standard: LED Exit signs $50/year savings new sign cost $30 no relamping = reduced maintenance costs no burnouts = increased safety less than 5 watts per sign.

78 Neon replacement and Signage Specialty applications Decorative lighting Merchandising do we really need the lights on?

79 First Stop: USGBC.org

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82 Two paths to gain energy points: LEED for Retail as of February 2008 LEED NC whole building requires modeling includes process loads 2-pt. mandatory minimum 14% savings (based on $) points are not based on ENERGY STAR LEED CI interior only points for categories lighting = 3 pts. lighting controls = 1 pt. hvac = 2 pts. envelope = 1 pt. equipment and appliances = 2 pts. points based on ENERGY STAR for equipment & appliances The Current NC is challenging: LEED NC whole building requires modeling includes process loads 2-pt. mandatory minimum 14% savings (based on $) points are not based on ENERGY STAR modeling is difficult no appliance baselines spec d no prescriptive path offered confusion about qualifying appliances

83 Suggested Prescriptive List: Jan ENERGY STAR CEE Tier II CA Rebates FSTC Slated for ENERGY STAR

84 Modeling and Prescriptive paths also include water use. For both NC and CI: 20% reduction earns 1 point & 30% reduction earns 2 points. How to get Energy points in the kitchen for LEED CI:

85 Energy points directly related to ENERGY STAR in CI For all ENERGYSTAR eligible equipment and appliances installed in the project, including appliances, office equipment, electronics, and commercial food service equipment (but excluding HVAC, lighting, and building envelope products): 70%, by rated-power, of ENERGYSTAR eligible equipment and appliances shall be ENERGYSTAR rated (1 point); OR 90%, by rated-power, of ENERGY STAR eligible equipment and appliances shall be ENERGYSTAR-rated (2 points).

86 At the present time, LEED CI is the most user-friendly approach for food service. LEED works for Banks! PNC has 40+ Green Branches

87 Is food service next? Is food service next?

88 Conclusion Huge opportunity to save energy! Approach the challenge step-by-step. Energy efficiency has a positive return-oninvestment (and the environment)!