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Foodservice Facilities Engineering and Architecture
Chapter 8 Foodservice Facilities Engineering and Architecture
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Chapter 8 Overview This Chapter:
Describes the primary considerations to be addressed by facilities planners to ensure the most economical use of energy in foodservice operations. Provides a basic understanding of the primary utilities used in foodservice. Describes the construction of hoods & ventilation systems in kitchens, dishwashing rooms, & service areas. Lists the most commonly used finishes for floors, ceilings, & walls in foodservice operations. Describes the methods for reducing sound. Discusses the effects of lighting levels on productivity & safe food handling, & offers recommendations for levels.
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Engineering Systems The engineering of a hotel dining facility, a complex restaurant, or a large institutional foodservice requires the expertise of architects & professional engineers. Engineering systems include: Water Systems Electrical Systems Gas Systems Steam Systems
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Water Systems Foodservice operations make significant use of water for cooking, ware washing, & waste removal. Relevant Costs: Metered cost of cold water. Energy required to heat water. Sewage costs of disposing of waste water.
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Water Consumption Equipment Item Hot-Water Consumption
Gallons (liters) per hour Low High Vegetable sink 15 (57) Triple-compartment pot sink 45 (170) 60 (227) Prerinse spray for dishes Bar sink (three-compartment) - 20 (76) Lavatory 3 (11) 5 (19) Utility sink Coffee urn Single-tank dish machine 50 (189)
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Water Supply & Drain Locations
Decisions about the location of water supply & drains are important considerations in the design & layout process. It is far less expensive to add a faucet during the design phase than after the facility has been opened. Supplying water to steam tables to fill the hot-food wells, to chef’s tables, to kettles & tilting skillets, & to server stations is likely to save steps (& therefore labor costs).
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Water Supply Hardware - Examples
Sink Faucet T & S Brass Pre-Rinse Kettle Filler Waste Lever + Drain
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Water Heating & Energy Conservation
A water heater uses less energy than a range top to heat the same amount of water. Hot tap water should thus be used for cooking whenever possible. Water should be heated only to the temperature needed. Heating the entire supply of kitchen water to 180ºF is highly inefficient when only the final rinse of the dish machine needs water at such a high temperature. Hot-water boosters should be located within 5 feet of equipment that needs 180º F (60º C) water for sanitizing. Longer distances cause heat loss in the pipes. Spring-operated valves on the kitchen & rest room faucets save water.
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Water Conditioning Systems
Used to remove mineral deposits from the water supply. Used with: Dish machines Coffee brewers Steamers Ice Machines Beverage systems Everpure Conditioning System
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Electrical System Design Principles
Foodservice equipment must match the electrical supply characteristics of the facility. Selecting equipment at the highest available voltage is preferred. Three-phase connections are preferred for motors. Select the method for connecting the electrical equipment to the power source. Permanently installed equipment should be direct-wired. A male & female adapter (plug) can be used for equipment that will be moved or frequently disconnected. Electrical characteristics & types of connectors should appear on the mechanical drawing, in the equipment specification, & on the order for the equipment.
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Electrical Systems Electrical energy conservation requires an understanding of the rate structures employed by utility companies. Two basic rate structures: Step Rate Demand Charge
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Gas Equipment Selection Considerations
Operational Preferences: gas offers a high degree of control over the heat in a pan Durability: in some applications, gas burners are less durable than electric Initial Cost: gas fired kettles & tilting skillets tend to be more expensive than electrical counterparts Ventilation Requirements: Combustion gases from burning gas must be vented to the outside
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Relative Energy Consumption
Equipment Electrical BTUs Gas BTUs Kettle 41,000 52,000 Fryer 72,000 110,000 Convection Oven 38,000 55,000 Combi-Oven 190,000 Steamer 61,000 90,000 However …..
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Relative Energy Consumption
Figures favoring electricity (last slide): Do not reflect how the actual connected load & energy usage for a given type of equipment may vary significantly among manufacturers. Do not reflect how much energy goes into the food itself. Do not reflect relative costs per BTU of electricity versus gas. These relative costs vary from region to region.
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Conservation Principles
Select equipment that is enclosed and/or insulated over open cooking vessels – steam jacketed kettles rather than large stock pots. Cook foods in the largest quantity possible. Cook at the lowest temperature possible. Monitor preheating for equipment – don’t permit ranges to be left on all day a full blast! Monitor the demand curve for electricity.
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Steam - Advantages Transfers energy to food rapidly.
Prevents much of the loss of nutrients, color, & texture that occurs when vegetables are boiled in a stock pot. A moderate, uniform cooking medium. Requires little or no warm-up time; thus preheat time losses are minimal. Cooking times are usually much shorter using steam equipment than they are using range-top cooking or boiling.
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Uses of Steam Direct steam cookery involves introducing steam into a cooking compartment, where it comes into direct contact with food Steamers Combi Ovens Indirect steam cookery uses steam to heat the metal walls of the cooking vessel Steam-jacketed kettles A third use of steam in the commercial kitchen is as a heat source for other purposes. Hot water in dish machines Heated make-up air in ventilation systems
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Heat Transfer Steam coils: Steam injectors:
A metal tube into which steam is introduced & where it condenses, giving off its latent energy in the form of heat that radiates from metal tubes and/or fins on the outside of the coil Steam injectors: Transfer heat by allowing the pressurized steam to escape into another medium, such as water or air. In some dish machines, injectors are submerged in the tank &, when charged, expel steam directly into the water to heat it.
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Selection Example: Three Kettles (see Cleveland Catalog Sheets)
MODEL KEL-25-T KGL-25-T KDP-25-T Energy Electric Gas Direct Steam Requirements 9.8 KW 90,000 BTU 50 lbs/hr Converted 33,447 BTU 50,000 BTU Rate $.07/KW $.0055/1000 BTUs $.0074/1000 BTUs Cost for 100K BTUs $2.05 $.55 $.74 Cost/Hour of Operation $.69 $.50 $.37 Cost/Year of Operation $430.56 $312.00 $230.88 Base Price $15,790 $19,340 $7,290
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Selection Example: Three Kettles Assumptions & Discussion Points
Utility Costs are examples – actual costs vary by locality Utility loads taken from catalog sheets, except for steam consumption of Model KDP-25-T. Assumption: 20 psi, ½” steam line will consume 50 lbs steam/hour One year’s operation – 624 hours Prices are “retail” & do not reflect bid prices Discussion Points Why is the steam unit less expensive to buy? Given these rates, which is the most cost-efficient alternative?
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Ventilation Systems The successful removal of heat & air that is laden with grease particles & food odors requires a well-designed hood exhaust system. Hoods remove air, water vapor, grease, & food odors from the kitchen range area & air & water vapor from dishwashing rooms. The basic functions of a kitchen ventilation system are to capture the air heated by the cooking process, remove as much grease from it as possible, exhaust the heated air to the outside, & resupply or make up the air removed from the kitchen.
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Hood Sizing Determining the exhaust & supply requirements for a hood.
Expressed in “cubic feet per minute” or CFM. Two Factors: The amount of heat generated by the equipment. The design of the hood canopy itself. Ventilation minimum requirements usually set by governmental code. The two most commonly used devices for capturing grease from the air as it passes through the hood canopy are filters & extractors.
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Three Different Filter Designs
Baffle Filter 50% - 60% Efficiency Extractor 80% – 90% Efficiency Extractor with Water Wash
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Supply (“Make-Up”) Air Design
There are three basic approaches to introducing makeup air in a kitchen ventilation system: Discharging air inside the hood. Discharging air along the face of the hood. Discharging air from separate registers.
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Supply (“Make-Up”) Air Design
Short-Cycle Design (“Rains” under Hood) Supply from Face of Hood (Requires Tempered Air) Supply from Register in Room (Requires Tempered Air)
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Fire Suppression System Comparison: Chemical vs. Mist
Dry/Wet Chemical: Separate system installation. Limited supply of chemical. Chemical difficult to clean from equipment after discharge. Works over all types of equipment. Wide acceptance. Water Mist: Integrated with building sprinkler system. Unlimited supply of water. Water easily cleaned from equipment after discharge. Requires special nozzles over fryers. Not widely accepted.
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Air & Humidity Control The Dishroom
Since warm air will hold more moisture than cool air, when moist warm air is cooled, water vapor condenses. Cool air containing less moisture increases the amount of moisture that can evaporate from the skin, & therefore is more cooling & comfortable. Unfortunately, in the dishroom, the air is often very moist & the temperature extremely high. Food facilities planners must insist that architects & engineers design into the HVAC (heating, ventilating, & air-conditioning) system a sufficient amount of air supply & exhaust to keep the moisture level as low as possible.
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Conveyor Systems For moving materials from one place to another, at maximum speed & with a minimum effort. Reduce labor by moving materials mechanically. Common use: trays; soiled dishes. Various types of belts depending on application (slats, pins, rollers, links). Requires: Planning for rate of flow at both ends. Buffer at unload end. Sound barriers. Access for cleaning & maintenance. Avoid vertical runs!
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Utility Distribution Systems
Locates the utility services in a stainless-steel raceway that is custom-fabricated according to the design of the facility. Offers three advantages: Unlike connection points built into permanent walls, connections in the raceway can be added, removed, or relocated with relative ease should the equipment change. Connections from the raceway to the equipment are well above floor level, making the cooking areas easy to clean. Electrical & plumbing contractors at the job site need to make only one or two physical connections to the utility distribution system, rather than multiple connections for each piece of equipment.
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Utility Distribution Systems
Route utilities to equipment within a stainless steel case. Single connections to building electric, water, & gas supplies. Often integrated with hood systems. Courtesy of AVTEC Industries
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Heat Recovery Systems Capture energy from sources that exhaust heat & use it to make hot water. Sources: Refrigeration Compressors Ventilation Uses: Dish Machine Cooking
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Foodservice Facilities Architecture
The specification & construction of building surfaces are usually the responsibility of the architect in new or renovated foodservice facilities. However, the architect often asks the foodservice consultant and/or the owner for recommendations on the types of finishes that are desirable.
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Foodservice Facilities Architecture Finishes: Floors
FOODSERVICE AREA RECOMMENDED FLOOR FINISHES Kitchen Quarry tile Dishwashing Quarry tile with Carborundum Storerooms Sealed concrete Wash-down rooms Quarry tile with Carborundum; quarry tile; sealed concrete Receiving Quarry tile; sealed concrete Offices Quarry tile; vinyl tile; carpet; wood Employee rest rooms Quarry tile; vinyl tile; unglazed ceramic tile; terrazzo Corridors, back Vinyl tile; unglazed ceramic tile; sealed concrete; Corridors, public Vinyl tile; unglazed ceramic tile; carpet; terrazzo Dining rooms Quarry tile; unglazed ceramic tile; carpet; terrazzo Public restrooms Quarry tile; unglazed ceramic tile; terrazzo Service areas
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Foodservice Facilities Architecture Finishes: Walls
FOODSERVICE AREA RECOMMENDED WALL FINISHES Kitchen, range section Structural glazed tile; glazed ceramic tile Kitchen, cold-food section Structural glazed tile; glazed ceramic tile; concrete block with epoxy paint Dishwashing Storerooms, dry stores Concrete block with epoxy paint Receiving Wash-down rooms Offices Painted drywall Employee rest rooms Glazed ceramic tile; concrete block w/epoxy paint Corridors, back of the house Concrete block with epoxy paint; painted drywall Corridors, public Decorative wall selected by interior designer Dining rooms Public rest rooms Glazed ceramic tile; decorative wall Service areas Glazed ceramic tile; concrete block with epoxy
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Foodservice Facilities Architecture Finishes: Ceilings
Common ceiling materials are: Acoustical tile Drywall, painted Plaster, painted Wood, sealed or painted Exposed concrete Fiberglass Aluminum or other metal Dropped ceilings with washable acoustical tile are most common in foodservice areas.
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Foodservice Facilities Architecture Controlling Noise
Acoustical ceilings. Sound-deadening coatings on the underside of stainless-steel work surfaces . Remote compressors for reach-in & especially for walk-in refrigerators & freezers. Electronic transmittal of orders to display screens in the preparation areas, rather than by servers shouting out the orders to the cooks. Low-volume background music in the workplace (such music tends to discourage radio owners from playing their sets full blast in the kitchen). Physical separation and/or enclosure of dishwashing & pot washing from other parts of the kitchen with walls designed to prevent sound transmission.
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Foodservice Facilities Architecture Lighting
In order to establish light levels that can assist the eye in seeing more efficiently, five factors must be considered: Time. Size. Contrast. Brightness. Sound.
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Foodservice Facilities Architecture Lighting Recommendations
SPACE FOOT CANDLES Kitchen Work Area 30 – 40 Storeroom Cashier 50 – 60 Loading Platform 20 – 25 Building Entrance 10 – 20 Rest Room 20 – 30 Hotel: General Guest Areas Accounting & Bookkeeping Offices 100 – 150 Dining Rooms Quick Service 40 – 50 Casual Dining White Tablecloth 5 – 15
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The End Copyright © 2008 John Wiley & Sons, Inc.
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