Supermarket Chain’s Experience with GREENing CKV OPERATIONS

1. Supermarket Chain’s Experience with GREENing CKV OPERATIONS by Robert Ajemian, MSPH President - Green Kitchen Designs Inc. www.GreenKitchenDesigns.com AHR EXPO BOOTH #2731

2. TAKE –HOME MESSAGE 1) GREEN CKV designs CAN and DO work for large supermarket commercial kitchens 2) A myriad of challenges WILL arise that require ONGOING commitment throughout the construction installation process 3) Traditional plan and spec model deficient- Empowerment of a CKV professional is IMPERATIVE and awarding CLEAR points for LEED accreditation is overdue

3. OVERVIEW • Background • Design Challenge • What innovations/knowledge was used to design GREEN CKV systems • What additional green concepts were used from store #1 through store #2 • Challenges to implement the designs • Outcomes • Advice to Concerned Parties

4. Background • LARGE NATIONAL CHAIN WITH WARM & FUZZY ORGANIC FEELING • FEATURES LARGE VARIETY OF IN-STORE PREPARED FOODS • DECENTRALIZED MANAGEMENT • SENSITIVE ALTERNA-DUDE STAFF • DIFFICULT TO ESTABLISH WHO THE DECISION-MAKER WAS

5. Background • “GREEN” ARCHITECTURAL MANDATE AND PRODUCT OFFERING , BUT… • NO GREEN ENGINEERING MANDATE • CKV CONSULTANT SUGGESTED GREEN CONCEPTS • NO FORMAL ATTEMPT AT LEED RATING • EVEN IF SO, LACK OF CKV IN NEW CONSTRUCTION HINDERS PROCESS • ENGINEER USED GREEN CKV CONSULTANT TO DESIGN JOB BUT…….. • CKV CONSULTANT NEVER VESTED WITH ANY AUTHORITY TO PROJECT MANAGERS

6. DESIGN CHALLENGE - HOODS • SEVERAL TYPES OF COOKING • MAIN 36’ PREPARATION KITCHEN • HOODS ON STORE FLOOR • SUSHI BAR /ROTISSERIE/ SMOKER/ TRATTORIA • EXPENSIVE ELECTRIC COSTS-17c Kwh • Need to minimize exhaust CFM • HOODS FOUND ON TWO FLOORS • TWO SYSTEMS REQUIRED - NFPA 96 • DUCT SPACE AT A PREMIUM • TYPE I & II HOODS COMBINED IN SAME SYSTEM

7. DESIGN CHALLENGE- SMOKE AND ODOR CONTROL • REQUIRED DESPITE ROOF DISCHARGE • HIGH POPULATION DENSITY-MANHATTAN • PREVIOUS HISTORY OF COMPLAINTS FROM UNCONTROLLED STORES • PROBLEMATIC PAST EXPERIENCE WITH POLLUTION CONTROL EQUIPMENT • UNDER SIZED UNITS LEAD TO COMPLAINTS

8. MAIN DESIGN GOALS • UTILIZE MINIMUM AMOUNT OF EXHAUST AIR VOLUME TO EFFECTIVELY CAPTURE COOKING EMISSIONS AND MINIMIZE SYSTEM COMPONENTS • COMBINE TYPE I AND TYPE II SYSTEMS TO CONSERVE DUCT SPACE • USE PROPERLY SIZED POLLUTION CONTROL EQUIPMENT WITH RESERVE CAPACITY • TO ACCOMMODATE FUTURE EXPANSION • TO MINIMIZE PROBALITY OF COMPLAINTS • MORE FOCUS ON OPERATING vs. CAPITAL COST

9. DESIGN SOLUTION - HOODS • MAIN KITCHEN HOODS - HIGH VELOCITY FRONT SLOT HOOD WAS SELECTED WITH ADJUSTABLE BAFFLES • ESTIMATED 40% REDUCTION OVER IMC VENTILATION RATES • FLOOR HOODS- WERE FILTER HOODS • LESS EXPENSIVE • HOODS HAD ADJUSTABLE BAFFLE “BLAST GATE” TO HELP TO BALANCE OUT SYSTEM • ADVANCED HOOD FILTERS USED TO REDUCE LOADING ON ELECTROSTATIC PRECIPITATOR

10. DESIGN SOLUTION-HOODS • WHERE PHYSICALLY POSSIBLE; PARTIAL SIDE PANELS WERE INCLUDED • THESE WERE LATER DISCARDED BY ARCHITECT WHO DIDN’T LIKE THEIR APPEARANCE • WHERE PHYSICALLY POSSIBLE; HOOD DEPTHS WERE INCREASED • AGAIN ARCHITECT DISALLOWED THIS ON THE MAIN MARKET FLOOR

11. MAIN KITCHEN HOOD

12. DESIGN SOLUTIONS –REPLACMENT / MAKE-UP AIR FIRST STORE ; COOLING WAS SPECIFIED FOR THE MAIN KITCHEN • FRONT DISCHARGE GRILLS WERE USED TO THRUST COOL AIR INTO THE KITCHEN (75X18’) • 95% OF AIR WAS REPLACED SECOND STORE; KITCHEN CONNECTED TO MAIN STORE • SO 60% MINIMALLY HEATED AIR WAS DISCHARGED IN REAR PLENUM • BALANCE WAS SUPPOSED TO BE COOLED TRANSFER AIR FROM MAIN FLOOR

13. 95% MAKE-UP AIR

14. DESIGN SOLUTION – SMOKE AND ODOR CONTROL • STORE HAD USED ELECTROSTATIC PRECIPITATORS IN THE PAST BUT THEY HAD BEEN UNDERSIZED • ELECTROSTATIC UNITS WERE SIZED FOR REDUNDANCY AND EXTRA CFM CAPACITY • BOTH STORES HAD 50-60% MID-RANGE EFFICIENT ADVANCED HOOD FILTERS TO REDUCE PRECIPITATOR LOADING/SERVICE

15. DESIGN SOLUTION – SMOKE AND ODOR CONTROL • BOTH STORES USED VFD • TO OPTIMIZE CFM • LENGHTHEN MOTOR LIFE • SMALLER HP MOTOR (STARTER COILS) FIRST STORE USED DOUBLE PASS SYSTEM WITH EACH PASS RATED FOR 95% (0.3 UM) REMOVAL • CRITICAL BECAUSE ONE POWER SUPPLY WENT BAD AND UNREPORTED FOR SEVERAL MONTHS

16. DESIGN SOLUTION – SMOKE AND ODOR CONTROL SECOND STORE • WENT TO SINGLE PASS AND MERV 17 CLASS I MEDIA FILTER SAFETY • TO SAVE ON DETERGENT COSTS • DETERGENT COSTS WERE REDUCED BY 40% BUT GAINS PARTIALLY OFFSET BY COST OF MEDIA FILTERS • WENT TO DOUBLE PASS CARBON TO DOUBLE CARBON LIFE • FAN AND VFD WERE WISELY CHOSEN WITH NEXT SIZE MOTOR (25 hp INSTEAD OF 20 Hp)- EXTRA CAPACITY (THANK GOODNESS)

17. DOUBLE PASS ELECTROSATIC PRECIPITATORS

18. OUTCOME • FIRST STORE WAS QUITE SUCCESSFUL IN ENERGY SAVINGS AND TO DATE NO ODOR COMPLAINTS THOUGH MAINTENANCE COSTS ARE HIGHER- VERY GOOD RESULT WITH CFM REDUCTION-LESS THAN DESIGN • SECOND STORE WAS MORE SUCCESSFUL IN CONTROL OF COOKING EMISSIONS BECAUSE OF REDUCED FILTRATION COSTS- LESS SO IN ENERGY SAVINGS DUE TO POOR DUCTWORK and BALANCING DIFFICULTIES

19. OUTCOME WHAT CHANGED FOR WORSE? • DESIGN – NO • IT WAS IMPROVED • PRODUCT MANUFACTURER-YES • QUALITY AND SUPPORT DECREASED • CONTRACTOR- YES • POOR DUCTWORK AND WORK QUALITY • OVERSIGHT MANAGEMENT-YES • STORE CONSTRUCTION MANAGER WAS INEXPERIENCED

20. WHERE’S THE GREEN ? (INITIAL CAPITAL COSTS)

21. EST. ANNUAL HEATING SAVINGS- $4927

22. Est. Annual Cooling Savings-$ 3636

23. FAN AND TOTAL ESTIMATED ANNUAL OPERATING ENERGY SAVINGS FAN OPERATING ENERGY SAVINGS – • DECREASE VOLUME VS INCREASE S.P. • 7672 CFM@6”w.g. vs 12600 CFM@5”w.g. • Approximately 10 HP vs 14 HP for utility set type TOTAL EST. ANNUAL ENERGY SAVINGS HEATING - $ 4,927 COOLING - $ 3,636 FAN - $ 4,000 TOTAL $ 12,563

24. How can we improve –OWNERS? • EITHER COMMIT TO GREEN DESIGN AND ITS COSTS ………….OR DON’T • INSTRUCT ARCHITECTS TO SEEK GREEN DESIGNS FROM CKV EXPERTS • EXPECT TO PAY FOR A QUALTY DESIGN AND JOB • DON’T AUTOMATICALLY CAPITULATE WHEN A LOW BIDDER WINS WITH SUBSTITUTED EQUIPEMENT

25. How can we improve - ARCHITECTS? • ARHITECTS NEED TO EITHER GRASP NEWER CKV DESIGN ENHANCEMENTS OR AT LEAST BE OPEN TO CONSIDER THEIR VALUE vs AESTHETICS • SIDE PANELS • DEEPER HOODS • PLACEMENT OF HOODS • MAKEUP AIR DELIVERY CONCEPTS • PUSH FOR LEED POINTS THROUGH AIA/USGBC FOR WELL-DESIGNED CKV

26. How can we improve- ENGINEERS? • ENGINEERS GET UP TO SPEED NOW or EMPOWER YOUR CKV DESIGNER • USE THAT DUCTILATOR- IT’S EASY • DO NOT HESITATE TO REJECT POORLY DESIGNED DUCT SHOP DWGS • ENFORCE YOUR DESIGNS WITH CONTRACTORS

27. How can we improve – MANUFACTURERS/CONTRACTORS MANUFACTURERS • NEED TO PROVIDE MORE ACCURATE S.P. LOSS DATA THROUGH THEIR EQUIPMENT • NEED TO PROVIDE BETTER QUALITY CONTROL • BETTER SHIPPING PROTECTION FOR PRODUCTS CONTRACTORS • DO WHAT THEY HAVE AGREED TO DO IN A CARING AND CONCERNED WAY • STOP LYING!

28. How Can We Improve –CKV EXPERTS AND ASHRAE • EMPHASIS THAT OUR ROLE IS MORE THAN JUST A VENDOR AND ASK ENGINEER TO ESTABLISH OUR AUTHORITY AND VALUE • SHARE ANY SUCCESSFUL ATTEMPTS FOR LEED POINTS WITH COLLEAGUES • PERHAPS INSTITUTE A CERTIFICATION PROCESS FOR CKF DESIGNERS • HANG IN THERE- IT WILL GET BETTER

29. TAKE –HOME MESSAGE • 1) GREEN CKV designs CAN and DO work in large commercial kitchens • 2) A myriad of problems exist that require attention in ADVANCE and power to solve as more inevitably come up • 3) Traditional plan and spec model falls short- the attention and empowerment of a CKV to the design team is necessary- and it isn’t free