Identifying the Hidden Costs of Airborne Kitchen Grease Eric Dyer FilterShine USA Airborne Kitchen Grease (AKG) a costly by-product of commercial cooking AKG: Presentation Agenda Identify primary grease collection device, its role and code definition Define responsibilities for grease removal Identify how to Monetize & Minimize this cost Identify how AKG impacts performance Reduced airflow Increased fire hazards Labor costs Unique volume and type of AKG Effectiveness of cleaning this grease Environmental impacts Implementing proactive measures Reduce overhead Gain a competitive advantage EPA compliant 1
Opening Vignette Hood Filters are the Primary Grease Collection Device Capture grease-laden vapors produced from cooking Standard filters: ~ 33% capture rate from clean functioning filters High Efficiency (HE) filters: ~ 69% capture rate from functioning filters Prevent flames and flammable debris from entering the exhaust duct Clean functioning filters minimize the buildup of grease in the ventilation system and greatly reduce the risk of fire NFPA 96 on Hood Filters (Slide 1 of 3) 6.1.1 - Listed grease filters, listed baffles, or other listed grease removal devices for use with commercial cooking equipment shall be provided 6.1.2 - Listed grease filters and grease removal devices that are removable but not an integral component of a specific listed exhaust hood shall be listed in accordance with UL 1046 6.1.3 - Mesh filters shall not be used unless evaluated as an integral part of a listed exhaust hood or listed in conjunction with a primary filter in accordance with UL 1046 - Example: Disposable Wool Filters 2
NFPA 96 on Hood Filters (Slide 2 of 3) 6.2.3.1 Grease filters shall be listed and constructed of steel or listed equivalent material 6.2.3.2 Grease filters shall be of rigid construction that will not distort or crush under normal operation, handling, and cleaning conditions * Disposable filters that can be crushed by hand do not meet this standard 6.2.3.3 Grease filters shall be arranged so that all exhaust air passes through the grease filters NFPA 96 on Hood Filters (Slide 3 of 3) 6.2.3.4 Grease filters shall be easily accessible and removable for cleaning 6.2.3.5 Grease filters shall be installed at an angle not less than 45 degrees from the horizontal 14.5.2 If airborne sparks and embers can be generated by the solid fuel cooking operation, spark arrestor devices shall be used To do their job well, filters must be clean and in top working condition Top Working Condition NFPA 96 defined No filters missing from hood All filters arranged vertically for proper drainage (weep) No missing baffles from filters ( teeth ) Properly fit without gaps greater than ⅛ (top or sides) Not dented or distorted to create gaps Not smashed or collapsed to restrict air flow Cleaned to bare metal (< ⅛ of buildup) To measure grease build up inside of a filter use a handheld luggage scale to weigh 3
Filters are a Listed Component of a Hood System Filters must be treated the same as the rest of the hood 11.6.1 - Upon inspection, if the exhaust system is found to be contaminated with deposits from grease-laden vapors, the contaminated portions of the exhaust system shall be cleaned by a properly trained, qualified, and certified company or person(s) acceptable to the authority having jurisdiction. 11.6.2 - Hoods, grease removal devices, fans, ducts, and other appurtenances shall be cleaned to remove combustible contaminants prior to surfaces becoming heavily contaminated with grease or oily sludge. What about Internal surfaces??? Video: 3 Pounds of Grease Inside of Restaurant Filters Exhaust Hood Manufacturers on Hood Filters Exhaust hood manufacturers recommend high volume restaurants replace exhaust hood filters every 6-months. 2-years for all other hood filters to remain fully functional The life of a filter will depend the type of filter, how well it s maintained, and the amount of grease, debris and heat Stainless steel last longer than aluminum or galvanized Heavy-duty filters vs. Standard-duty have longer life Filters fail internally as the metal wears and tears from cleaning chemicals, heat and handling Health Department on Filters Grease is rancid vegetable and animal fat It is illegal to have grease dripping from hood filters onto cooking surfaces FDA Food Code - Chapter 4-204.11 Ventilation Hood Systems, Drip Prevention Exhaust ventilation hood systems in food preparation and warewashing areas including components such as hoods, fans, guards, and ducting shall be designed to prevent grease or condensation from draining or dripping onto food, equipment, utensils, linens, and single-service and single-use articles. 4
Whose job is it to clean filters? Contractor vs Staff Cleaning Responsibilities Restaurant operators are responsible for cleaning everything in the exhaust system that is removable on a routine basis to prevent heavy buildup (daily, etc) Grease Removal Devices and BMP for cleaning Trays (drain and hand wash) Cups (drain and hand wash) Baffles (hand wash) Filters (soak daily or boil clean) Hood cleaners are responsible for cleaning everything in the exhaust system that is not removable on a routine basis to prevent heavy buildup (quarterly, etc) Quarterly cleaning of hood filters is not enough How well is your kitchen staff cleaning your filters? Methods Warewash machines Hand Cleaning Soaking Boiling Pressure Washing Frequency Daily Weekly Every other week Monthly Only the hood cleaner does 5
Pressure Washing Filters = Bad Idea Primary method that hood cleaners use Sodium/Potassium Hydroxide: ph 14+ Applied undiluted - it eats the metal High PSI damages filters and weld points Most of the chemical runs directly off the filter Inside of filter is still grease clogged Cleaning outdoors is illegal: Storm drains Untreated straight to fresh water Issues Caused by Indoor Cleaning Cleaning filters in sinks causes grease clogged floor drains Cleaning in warewash - damages & cross contamination Warewash machines, some not connected to grease traps Municipal Sewer System issues from grease and chemical SOAP in the Sewers - Dr Joel Ducoste NC State Grease Trap Use Ordinance Charlotte, NC Ordinance No Grease in Drains - treat as solid waste Posters required at every drain leading to grease traps Must have written procedures for handling sources of floatable oils, fat or grease originating within facility Must have written Waste Minimization Plan Must train employees on proper grease disposal and maintain documentation that training was received Is filter grease exempt? 6
Grease Traps & Interceptors: Where does the grease come from Case studies by Trap Manufacturers Volume: 500 meals/day 0.035 lbs/meal x 90 days = 1,575 lbs/qrtr (4) 55 gallon drums of pure grease per quarter! 0.025 lbs/meal x 90 days = 1,125 lbs/qrtr This grease trap would have to be pumped out every 2- days to maintain efficiency NOTE: Neither concept does any dishwashing on site Traps are not always capable of handling every situation imaginable without overflowing their discharge point. Grease Traps & Interceptors: Where does the grease come from Up to 70% of the grease in traps, interceptors and floor drains originates from hood filters - no other major source at fast food establishments Only 30%! What are the cost of AKG? 7
What are the cost of AKG? Water Blue/Grey Employee Payroll OverTime Social Security Federal FICA State & Local Manager Payroll Replacement Filters 1 Hour a Day on Filters = $12,164/year Doesn t include manager s time INSURANCE EXPERIENCE RATING Emergency Grease Trap Pump Outs Most Dangerous Kitchen Cleaning Task Grease Clogged Floor Drains = Line Jetting What are the cost of AKG? Cost Per Cost Per Cost per Filter Cleaning Month Cost per Year Payroll Employee(s) Hourly Wage $1.00 $10.00 $303.33 $3639.96 Soc. Security $0.08 $0.84 $25.48 $305.76 Fed Taxes $0.18 $1.76 $53.39 $640.68 FICA-Med $0.03 $0.29 $8.80 $105.60 State (W/H) $0.06 $0.61 $18.50 $220.00 Local $0.02 $0.20 $6.07 $72.84 Worker's Comp $0.09 $0.86 $26.06 $312.72 Water (commercial rate) $0.27 $2.67 $80.99 $971.88 Degreaser $1.19 $11.99 $359.70 $4316.40 Supervisor Costs $1.15 $11.15 $350.05 $4200.60 Emergency Grease trap service $0.04 $0.52 $15.79 $189.52 Electric $0.21 $2.21 $62.49 $749.88 Gas $0.00 $0.00 $0.00 $0.00 Filter Depreciation (3 Year Life) $0.04 $0.41 $12.44 $149.28 Drain Jetting Cost (Previous Yr) $0.14 $1.35 $40.83 $490 $3.35 $33.71 $1013.87 $12,164 *Does not account for injured workers, missed job time, increases in insurance, manager s time on the clock or damages to filters, equipment or warewash machines What are the cost of AKG? Filter Cleaning Cost Comparison 10 Filters Cleaned every day for 1-month $1600 $1400 $1200 $1000 $800 Kitchen Staff: 6.5 per meal Outsourcing: 1.4 per meal $1013 Kitchen Employees $600 $400 $200 $220 Outsourcing 0 Taxes on wages Wages Water Electric Line Jetting Grease Trap CO Dishwasher Chemical Replacing Filters Total Cost *Does not account for injured workers, missed job time, increases in insurance, manager s time on the clock or damages to warewash machines 8
AKG Performance Impacts Why baffles in a filter? 1) To permit air to pass freely and collect grease 2) To keep flames from entering the exhaust system 3) To allow fire suppression system chemicals to be pulled into the ductwork if the system is set off Air Flow: Speed is the key AIRFLOW 9
Reduced Airflow through filter Grease Build Up AIRFLOW Increased Surface Tension Grease Blockage Trapped Smoke Trapped Heat Airflow is now swirling Time to Clean the Filters Smoky hot kitchens are always a good motivator to get things done 10
Kitchen staff cleaning filters 3 pnds of sticky grease remain Outside looks clean for a short time Harsh chemicals and hand scrubbing pit metal Surface tension gathers grease quickly making the filter look dirty quicker Outsourcing Filter Cleaning Blocks Gone No Surface Tension AIRFLOW moving at Engineered Speed Clean Hood Filters - Allow Air to Pass Direct Unrestricted Air flows directly through the filters located directly above them This prevents smoky air from rolling out of the hood Filters over high grease producing equipment require More Cleaning Different cooking produces different types/sizes of grease molecules Chinese Grease: Large molecules and extremely sticky Steak Cooking Grease: Small molecules and similar to motor oil Indian Vegetarian Grease: Large molecules and very sticky 11
Clean Hood Filters - Allow Air to Pass Direct Unrestricted airflow moves at the speed engineers specified in design Grease clogged filters trap more heat in the hood and on the filters FLASHPOINT: Definition - Grease+Creosote 165F Spark Arrestor Filters - Clogs are very dangerous Auto Ignition for Grease+Creosote is 600F Air takes Path of Least Resistance (1 of 2) Filter Orientation All filters must be Vertical to facilitate drainage through weep holes in bottom of the filter Horizontally oriented filters change air resistance, airflow direction and trap and hold grease Correct fit (no gaps between filters snug fit) Filters must be same type and manufacturer Optimum performance requires equal air velocity over the entire length of the hood opening (as designed in engineering specs for kitchen) Air takes Path of Least Resistance (2 of 2) Filters Must be Clean Grease clogged filters do NOT drain (Weep Holes) Clogged filters slow airspeed - break engineer specs Slow air speed causes MORE liquid grease buildup Surface Tension Liquid forms and gets pulled through the system Filters Must All be Present (At all times while in use) Missing Filters Re-Direct Airflow Missing Filters or Baffles are a Major Fire Hazard (Especially over solid fuel cooking appliances) 12
Impact: Fire Suppression Systems Grease clogged filters slow air speed Slow air speed results in higher temperatures in hood Slow air speed causes grease fumes to remain in hood Fumes coat suppression nozzles, links and lines Grease fumes turn into drops and solidify High temperatures bake these drops into hardened carbon Carbon causes links do not release at the correct temp Hardened grease clogs suppression lines Pulley wheels at 90 degree bends do not operate Impact: Fire Suppression Systems Grease clogged filters do not allow suppression chem to be pulled into ductwork Grease and heat are fuel for a fire Average 3+ pounds inside of clean looking filters Filters are located behind most suppression nozzles Slow air causes more liquid grease to form - Throughout the entire system - Inside and outside of the exhaust fan - On the roof Grease can lead to structural damage to roof 2007 Boston Grease Fire Tragedy 15,000 pound air handlers Impact: Increased Fire Hazards Internal Filter Grease Buildup - A Hidden Deadly Problem 3 to 6 Pounds of grease buildup common (grease weighs 7 pnds/gal. - ready fuel for a fire) Grease fire burns ~2000 to 3000F Solid grease in filters liquefies at 350F Grease Clogged Filters - Creating the Time Bomb Slow air speed creates more grease buildup in filter Creates more grease buildup in ductwork More grease buildup on roof Filters are the 1st Line of Defense in a kitchen fire Fires get backdraft affect into ductwork Liquefied filter & ductwork grease are fuel for a fire Burning embers float past filter guarding entrance into grease/creosote covered ductwork 13
How to Inspect Hood Filters Look for corrosion, dents, holes, missing baffles, flattening of baffles and warping that prevent the filter from sitting snugly in the hood opening Look for grease build up between filter baffles (teeth) There should never be more than ⅛ of grease build up But how do you measure internal grease build up? How to Inspect Hood Filters Use a portable luggage/fish scale to weigh filters Most filters weigh around 3 pounds clean This is the ONLY feasible mean to determine internal grease load Any filters that show damage should be replaced to keep grease from getting further into kitchen exhaust systems Choosing the Right Type of Grease Filter Stainless Steel Aluminum Galvanized Baffle filters Box filters Bottom Clips or Top Clips Filter Sizing Spark Arrestor High Efficiency Filters Pollution Control Unit Filters 14
Choosing the Right Type of Grease Filter Does the cooking equipment burn solid fuel? Spark Arrestor Filters are required Mesquite, briquettes, charcoal and hardwood are all examples of solid fuel A spark arrestor is a steel screen mounted to a baffle filter. Its function is to stop flames, embers and sparks from finding their way into the hood exhaust ductwork High Efficiency Filters are rated for this use as well, but they are designed to restrict airflow, so they clog very quickly Choosing the Right Type of Grease Filter Does the exhaust system use a Pollution Control Unit (PCU)? PCUs require filters that remove 69%+ of the Grease Load at the hood level High Efficiency Filters PCU have additional internal filters that remove the remaining grease load and grease odors The problem is Out of sight, out of mind Proactive Measures Purpose Benefits 15
The Purpose of Filter PM Fire Prevention - remove fuel load and reduce heat Maintaining Proper Air Flow Increase Energy Efficiency: Lower temp in kitchen and less strain on fan motors and belts Limit grease buildup in hood, ductwork, exhaust fans, roof membrane, gutters and downspouts Limit grease buildup on HVAC condenser coils **A clean looking filter is the byproduct of proper maintenance, not the goal** Benefits of Filter Maintenance Facility Plumbing Management Limit grease in floor drains, traps/interceptors (up to 70% is from cleaning filters in sinks) Limit overflow of trap discharge point into municipal sewer (degreasers, hot water, grease) Protect warewash machine from damage, cross contamination and direct sewer pollution Protect the Environment Protect your company from EPA fines Decentralized enforcement - Apps on every website Every Citizen can act on behalf of the EPA Proactive Options for AKG Identify if you have a hood filter problem Use handheld scale provided Weigh dirtiest filter above highest grease producer Examine all filters for wear and tear Require a filter cleaning log from staff and maintain it 16
Proactive Options for AKG Identify cleaning frequency requirements from different hoods and cooking equipment Track monthly expenditures of degreasers, water and energy Monitor grease buildup on roof and HVAC units Replace hood filters Consider outsourcing filter cleaning Benefits of Outsourcing Filter Cleaning Filters are 100% clean - INSIDE AND OUT Worn out filters are replaced as part of the program Correctly sized filters are used as part of the program Filters are always installed correctly Eliminate the most dangerous kitchen cleaning task Eliminate up to 70% of the grease in your floor drains and grease traps Eliminate emergency grease trap service Eliminate costly line jetting Benefits of Outsourcing Filter Cleaning Airflow is restored to original system specifications Kitchens are cooler and energy is saved Exhaust fans save energy by not pulling through clogged hood filters Exhaust fan motors and belts last longer Greatly improve the fire safety of your exhaust system Greatly improve the airflow in your kitchen Creating cooler and cleaner kitchens Greatly reduce the temperature in your hood and ductwork Greatly decrease grease buildup in the system, exhaust fan and on your roof top 17
Filter Cleaning Comparison Kitchen Staff Daily A few times a week Weekly Bi-Weekly Monthly Outsourcing Cleaning Bin Program Weekly Every other week Monthly Bi-Monthly Filter Cleaning by Equipment Clean All Filters in these Hoods Kitchen Staff Cleaning Offsite Soak Tank Filters in Hoods over: Clean all Filters in Hoods - Wood/Charcoal Grills of this Type DAILY - Fast Food Grills/Fryers - 24-hour Grills/Flat Tops - Rotisserie, Charbroilers or Woks Filters in Hoods over: - Deep Fryers, Flat Top Grills - Moderate use Charbroilers 2 x per Week Cleaning of all Filters in Hoods of this Type Filters in Hoods over: Weekly Cleaning of all - High use Oven/Stove/Convection Filters in Hoods of this Ovens Type - Henny Penny Fryers - Moderate use Hoods Filters in Hoods over: - Low use Oven/Stove/Convection Ovens - Any other Low use hood Every other Week Cleaning of all Filters in Hoods of this Type Bin Program or Weekly Exchange of all Filters in Hoods of this Type Bi-Weekly Exchange of all Filters in Hoods of this Type Monthly Exchange of all Filters in Hoods of this Type Bi-Monthly Exchange of all Filters in Hoods of this Type Filter Cleaning by Type/Volume Type or Volume of Cooking Kitchen Staff Cleaning Offsite Soak Tank - Systems serving solid fuel Daily Cleaning of all Filters cooking operations in Hoods of this Type - Systems serving high-volume cooking operations, such as 24- hour cooking, charbroiling, or wok cooking - Systems serving moderatevolume cooking operations - Systems serving low-volume cooking operations, such as moderate use churches or senior centers - Systems serving low-volume cooking operations such as low volume use churches, day camps, seasonal businesses 2 or 3 times per Week Cleaning of all Filters in Hoods of this Type Bin Program or Weekly Exchange of all Filters in Hoods of this Type Bi-Weekly Exchange of all Filters in Hoods of this Type Weekly Cleaning of all Monthly Exchange of all Filters in Hoods of this Type Filters in Hoods of this Type Every other Week Cleaning of all Filters in Hoods of this Type (during season or when in use) Bi-Monthly Exchange of all Filters in Hoods of this Type (during season or when in use) 18
The Bottom Line Filters are the boss! Keep them clean inside and out, and they will take care of your facility Conclusion Questions? 19