1. Foodservice Facilities Engineering and Architecture
Chapter 8
Foodservice Facilities Engineering and Architecture

2. 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.

3. 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

4. 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.

5. 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)

6. 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).

7. Water Supply Hardware - Examples
Sink Faucet
T & S Brass
Pre-Rinse
Kettle Filler
Waste Lever + Drain

8. 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.

9. 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

10. 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.

11. Electrical Systems
Electrical energy conservation requires an understanding of the rate structures employed by utility companies.
Two basic rate structures:
Step Rate
Demand Charge

12. 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

13. 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 …..

14. 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.

15. 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.

16. 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.

17. 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

18. 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.

19. 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

20. 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?

21. 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.

22. 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.

23. Three Different Filter Designs
Baffle Filter
50% - 60% Efficiency
Extractor
80% – 90% Efficiency
Extractor with Water Wash

24. 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.

25. 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)

26. 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.

27. 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.

28. 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!

29. 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.

30. 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

31. Heat Recovery Systems
Capture energy from sources that exhaust heat & use it to make hot water.
Sources:
Refrigeration Compressors
Ventilation
Uses:
Dish Machine
Cooking

32. 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.

33. 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

34. 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

35. 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.

36. 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.

37. 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.

38. 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

39. The End
Copyright © 2008 John Wiley & Sons, Inc.