Hot Food Holding Cabinets, Steamers, and Fryers

RTF Meeting 5/5/2009

Project GoalGoal: Verify the electrical savings and cost

difference between standard units (CEE Tier I/Energy Star) and high efficiency (Tier II) units by using a developed energy savings spreadsheet for all three measures.

Project Timeline/HistoryStarted in October of 2008First Goal was to try and determine current ‘standard

practice’1. We hit the streets and determined large percent roughly

50% of market is used. However, we decided not to include based on discussion with RTF. # Re-sales/Efficiency/Cost

2. We then pursued new equipment and found some surprising data. Based on Discussion with Vendors and Best in Class

Study we found that a large percent of new equipment being purchased is already Energy Star or CEE Tier I rated.

We believe over 75% of new standard fryers and HFHCs are Energy Star, however approximately only 30 to 40% of steamers are Energy Star (Boiler Based vs. Connectionless)

Energy Baseline

Steamers Baseline (Actual)Approximately 30 to 40% of Market is Connectionless (Discussion

with Vendors)Best in Practice Report does not include AccuTemp (Developer of

‘Connectionless Unit’, Large portion of ‘Connectionless Market’) FSTC believes that approximately 60% of compartment steamers

can be replaced with connectionless (Increased Potential)

Project Timeline/History

EMP2, Inc. then developed a Tier II rating and incremental cost for all three measures.

HFHC already had a CEE Tier II rating. EMP2, Inc. developed Tier II rating based

on market penetration, vendor participation, and comparison to other Tier II programs.

Tier II Development The Tier II was developed from the Energy Star list of equipment for Fryers and

Steamers. Hot Food Holding Cabinets were already divided into Tier I and Tier II. The selection process would be one that we could implement for both Fryers and

Steamers. In general, the efficiencies of Fryers and Steamers are broken into Cooking Energy

Efficiency (HCE for Fryers and CEE for Steamers) and Idle Energy Rate (IER) with the two parameters not necessarily correlating to one another. Therefore our process would try to address both components.

It was decided that 50% of the top Cooking Energy Efficiency and the top 50% of the Idle Energy Rate would be the cutoffs, and then this would ensure that units within those two ranges would be the most efficient units within the population in both parameters. Then, the actual efficiencies would be adjusted to simpler and more usable values (i.e. 80.3% HCE rounded to 83%).

In addition, Incremental Cost would be determined for Fryers, Steamers and Hot Food Holding cabinets. There are many factors that affect equipment pricing that may or may not be directly energy related (i.e. components of computer controls, auto lift features) so incremental costs has to be determined on an individual measure basis and it is useful to compare like products from like manufacturers.

Fryers Applying the selection process yielded the following distribution for Fryers:

The HCE was rounded down to 83% from the original 83.7% and then for incremental cost reasons, the IER was adjusted from the original 891 IER to 850 IER.

Fryers - Rounded to 83% HCE and 850 IER

Category

total

units

# of Mfg

# of units

qualify (HCE)

HCE Base Range (%)

HCE Prem Range (%)

# of Mfg

# of units qualif

y (IER)

Base IER Range (W)

IER Prem Range (%)

# of Mfg

# of units qualify (for both HCE

& IER)

% Units

# of Mfg

% Mfg

   

Fryers 91 5 56 80.3 - 87.17 83.2 - 87.17 5 53 630 - 990 630 - 850 5 53 58% 5 100%

Fryer Incremental Costs Many factors affect the pricing of fryers such as computer

controls that may increase efficiency such as modulating heating elements and the timed heating of oil as are present in the Fry Master’s TC units (Tier II). Some aspects of computer controls are not energy efficiency related such as language settings, multiple programmable cook cycles, and display and voice features that are all included in the cost of computer controls.

Other factors that increase costs are auto lift features Increased insulation is definitely an energy improvement feature

along with shorter cook times, and higher production rates (Energy Star).

Because there are so many factors that contribute to pricing it is useful to concentrate on like products from like manufacturers.

Fryer Incremental Costs If we looked at the Fry Master list of products we’ll find some like items that we can

compare…

Factors that increase energy efficiency in fryers include: Frypot insulation, low-watt density elements, modulating power controls

According to Fry Master, the TC units (Tier II) have computer controls, as opposed to just solid state controls, that as a part of their function will modulate the heating elements to improve demand control. The Tier II units will start out with less power. They go through a subroutine to slowly heat the oil to save energy. These aspects, according to Fry Master, contribute to the increase in cooking energy efficiency. The TC (Tier II) units also have insulated fry pots while the standard units (Tier I) do not. Both Tier I and Tier II units are equipped with low watt density heating elements

Solid state controls are an improvement over mechanical controls

FryMaster Units Solid State Controls

Computer Controls

Increased Insulation

HCE IER Tier I Tier II Costs

RE14 x     83.6 821 x   $4,461

RE17 x     86.6 891 x   $4,730

RE22 x     83.7 864 x   $4,373

                 

RE14TC   x x 87.17 772   x $5,076

RE17TC   x x 87.17 772   x $5,582

RE22TC   x x 87.16 772   x $5,329

                 

Average Cost of RE14, RE17 & RE 22               $4,521

Average Cost of RE14TC, RE 17TC & RE 22TC               $5,329

Difference               $808

Steamers Applying the selection process yielded the following distribution

for Steamers:

For the 4-pan units, there is only one unit on the Energy Star list and so we can either disregard the 4-pan category entirely or use non-Energy Star units as the Tier I

Steamers Rounded Summary, 65% HCE and a tiered escalation for the IER

Category total units

# of Mfg CEE Base Range (%)

CEE Prem Range (%)

Base IER Range (W)

IER Prem Range (%)

units qualify

(for both

CEE & IER)

% Units

# of Mfg % Mfg

3-pan 13 9 55-70 65-70 102-330 102-220 3 23% 2 22%

4-pan 1 1 54.7 200  

5-pan 9 6 57-71 65-71 154-510 154-230 3 33% 3 50%

6-pan 24 6 62-73.1 65-73.1 160-500 160-250 14 58% 4 67%

Steamers Incremental Costs

For 3-pan Steamers we compared Market Forge units because Market Forge has a unit on Tier I and Tier II and found that the incremental cost between the Tier I and Tier II units are approximately $132. The difference being that the Tier II unit has a fully insulated cooking compartment while the Tier I unit does not.

For 5-pan Steamers, we did not have similar manufacturers with like products to compare pricing. We compared the Blodgett SBF-5 (Tier II) against the Vulcan Hart VPX5 (Tier I) because these two are very comparable units and the incremental cost was approximately $215. According to the cutsheets there was very little difference in the options except the fact that the IER for the Tier I unit was over twice the IER of the Tier II unit (550w vs. 220w). This can be reasonably attributed to both better insulation and possibly the controls during idling periods. Both units had the same cooking efficiency (68%).

For 6-pan Steamers, if we compared Accutemp which have units on both Tier II and Tier I then the incremental cost is $800.00. The Tier II unit is a higher power unit that allows for faster startup and cook time (17 kW versus 6 kW). However, to have this incremental cost more inline with the 3-pan and 5-pan we interpolated the incremental costs using the 3-pan and 5-pan pricing and are proposing $209 as the incremental cost for the 6-pan units.

HFHC HFHC are already divided into Tier I and Tier II based on the IER only. Up to 20 watts/ft³

qualifies for Tier II and up to 40 watts/ft³ qualifies for Tier I.

We chose to divide the population into half, three-quarters and full sizes with the following requirements:

Half: up to 12ft³ Three-quarters: 12ft³ to 20ft³ Full: 20ft³ and above

Then the distribution would be as follows:

Size Total Models

# of Mfg

IER Base Range (%) IER Prem Range (%)

# of Mfg # of models qualify (Tier

II)

% Models # of Mfg

% Mfg

Half 317 13 21 - 39.87 9.66 - 18 4 147 46% 4 31%

3/4 241 13 20.4 - 39.76 9.66 - 18.8 7 16 7% 7 54%

Full 169 13 20.1 - 35.5 4.76 - 9 98 58% 9 69%

HFHC Incremental Costs HFHC increase in efficiencies can come from better insulation, magnetic door gaskets,

auto door closures and Dutch doors.

For HFHC cabinets, we averaged the pricing of each categories from Tier II and compared them to costs from Tier I and we get the following incremental costs:

The Incremental Cost for the Half-size HFHC (10):$788.00We looked at a Cambro CMBH (Tier II) and a Hatco FSHC (Tier I). Both units are insulated but the insulation on the Tier II unit may be better than the Tier I. Also, the energy draw for the Tier I unit was just simply larger (rated 14.1 amps versus 9.1).

The Incremental Cost for the Three-quarter-size HFHC (4):$710.00We looked at a Cambro CMBH (Tier II) and a Henny Penny HHC-900 (Tier I). Both units are well insulated, have magnetic door gaskets, and Dutch doors. However, the energy draw for the Tier I unit was just simply larger (rated 17 amps versus 13.7).

The Incremental Cost for the Full-size HFHC (10): $1505.00For the Full-size units we looked at two InterMetro units that are roughly the same size, C569L (Tier II) and the C539 (Tier I). Both units were equipped with Dutch doors but only the Tier II unit had insulated doors. This could explain the difference in the IER of 14.8 versus an IER of 33.1.

CalculatorModified ASTM Calculation (Two-Mode Model, based

on Heavy Cooking Load, Idle Energy Rate, and Preheat Energy.

This was done due to current high efficiency parameters which was narrowed down to idle energy and cooking energy. If we want to include additional parameters such as light load cooking energy we will need to develop another Tier I and Tier II capacity rating and efficiency rating.

This information is very difficult to obtain. Only selected unit’s energy efficiency is given on FSTC website.

Hours of Operation based on ADL and Steamer Report

Hours of OperationHours of Operation based on ADL Report for

Steamers and Fryers and compared to other programs.

Hours of Operation for HFHC is basically a conservative number when compared to other programs.

93% of Market between Restaurants (Fast Food/ Dine-In), Lodging, and Retail. Feel comfortable using a deemed value.

Calculator (Hours of Operation)

Sensitivity AnalysisHFHC1.Hours of Operation (Conservative at 12

hrs/day instead of 15)2.Size of Units (Based on other models –may

want to include larger units)

Sensitivity AnalysisFryers1. Hours of Operation (Conservative at 10 hrs/day instead of 12)2. Utilization Factor (15% instead of 20%)3. Conservative lbs of Food Cooked4. Found that Light vs. Heavy Load Cooking doesn’t really vary

savings since the efficiency curve is relatively flat until very low loads <10%

Sensitivity AnalysisSteamers1. Hours of Operation (Conservative at 7.5 hrs/day instead of 12)2. Utilization Factor (20%)3. Conservative lbs of Food Cooked4. Found that Light Load increases energy consumption due to lower

efficiencies.5. Found that other product (frozen peas) increases cooking

efficiciency and increases cooking time. (Red Potato consumes more energy)

Savings

1. Open Items.