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Supermarket Chain’s Experience with GREENing CKV OPERATIONS by Robert Ajemian, MSPH by Robert Ajemian, MSPH President - Green Kitchen Designs Inc. President.

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Presentation on theme: "Supermarket Chain’s Experience with GREENing CKV OPERATIONS by Robert Ajemian, MSPH by Robert Ajemian, MSPH President - Green Kitchen Designs Inc. President."— Presentation transcript:

1 Supermarket Chain’s Experience with GREENing CKV OPERATIONS by Robert Ajemian, MSPH by Robert Ajemian, MSPH President - Green Kitchen Designs Inc. President - Green Kitchen Designs Inc. 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 1.Background 2.Design Challenge 3.What innovations/knowledge was used to design GREEN CKV systems 4.What additional green concepts were used from store #1 through store #2 5.Challenges to implement the designs 6.Outcomes 7.Advice to Concerned Parties

4 Background  LARGE NATIONAL CHAIN WITH WARM & FUZZY ORGANIC FEELING  FEATURES LARGE VARIETY OF IN-STORE PREPARED FOODS 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  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 DESIGN SOLUTION – SMOKE AND ODOR CONTROL

16 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) DESIGN SOLUTION – SMOKE AND ODOR CONTROL

17 DOUBLE PASS ELECTROSATIC PRECIPITATORS

18 OUTCOME 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) ITEM NET COST BASIS/EFFECT DOLLAR AMOUNT HOODS+100%+$20,000 PRECIPT/FAN 5000 CFM LESS -$ 20,000 EXHAUST DUCT $60/LF -$ 12,000 FIRE WRAP $40/LF -$ 8,000 MAKEUP AIR UNIT $1000/Ton AC (12 ) -$ 12,000 SUPPLY DUCT $10/LF -$ 2,000 DUCT LABOR $100/LF (Union) -$ 20,000 TOTAL CAPITAL COST SAVINGS -$ 60,000

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 vs  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 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


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