presentation by: richard young

Cold Hard Savings: How to Purchase and Operate Ice Machines

for Max Efficiency & Min Cost

February 18th 2014

Presentation by:

Richard YoungDirector of Education

Specializing in commercial food service

Promoting energy efficiency and performance

Celebrating 26 years of hard work!

The Food Service Technology Center (FSTC) is an

unbiased energy-efficiency research program

funded by California utility customers.

www.fishnick.com/handouts/02182014

Download Today’s Handouts:

Our Mission is to bring “MPG”

and Performance information to

the entire commercial food

service world.

Today’s Learning Goals

1. How to use the AHRI database and the

California Energy Wise incentives to find

energy-efficient ice machines.

2. How to use the FSTC online calculator to

estimate energy savings for efficient machines.

3. Understand what it means to “load shift” an ice

machine and how to accomplish load shifting.

Part One: 9:30 to 10:45

Purchase and Calculate

Part Two: 11:15 to 12:30

Load Shifting

30 Minute Break

Part One:

Purchase and Calculate

But First...

Some Background and Basics

Our First

Restaurant Field Monitoring

Case Study

1. Increased ice machine capacity

2. Ice machine on a timer: runs only at night

• 194 lb/day

• 12.2 kWh/100 lb

• 28.7gal/100 lb

• 18.6 kWh/day

• $880/year

• 570 lb/day

• 6.5 kWh/100 lb

• 26.4 gal/100 lb

• 7.25 kWh/day

• $ 340/year

@ $0.13/kWh

From: To:

Save $540 a year• quieter kitchen

• cooler kitchen

• more ice available

• reduce demand by 1 kW

That got us interested and we

started asking questions like...

Who uses ice machines?

• Everyone:

Hotels, schools, hospitals, churches,

restaurants, businesses, biomedical,

government, correctional, etc...

• And, many restaurants have multiple ice

machines.

Back of the envelope estimate:

At least 3,000,000 ice machines in US

Then we discovered an important

and unique resource:

The AHRI Online Database

AHRI Ice Machine Database

Air-Conditioning, Heating & Refrigeration Institute (AHRI)*

• Ice Harvest Rate (lb/24 hr)

• Potable Water Use Rate (gal/100 lb ice)

• Energy Consumption Rate (kWh/100 lb ice)

• Condenser Water Use Rate (gal/100 lb ice)

http://www.ahridirectory.org/ahriDirectory/pages/home.aspx

AHRI Directory of Certified Product Performance

ACIM – Automatic Commercial Ice-Makers* and Ice Storage Bins

* Changed from “Ice-Cube Machines” to now include continuous-type machines.

0 500 1000 1500 2000 2500

Energy Consumption (kW

h/100 lb)

Ice Harvest Rate (lb/24 hr)

Air‐Cooled Cube‐Type Water‐Cooled Cube‐Type

AHRI Database

Observation #1:Higher capacity machines use

less energy per 100 lb of ice

0 500 1000 1500 2000 2500

h/100 lb)

Air‐Cooled Cube‐Type Water‐Cooled Cube‐Type

AHRI Database

Observation #2:For a given capacity of machine,

energy use varies significantly

1994 ARI Data – Air-Cooled Cube Type

0 500 1000 1500 2000 2500

h/100 lb)

Air‐Cooled Cube‐Type

2005 ARI Data

(7.75 – 7.6) / 7.75 = 2% Reduction

Technology + Energy Star +

California Energy Wise +

DOE 2005 Energy Policy Act

= More Efficient Machines.

0 500 1000 1500 2000 2500

h/100 lb)

2012 AHRI Data

(7.6 – 6.5) / 7.6 = 14% Reduction

0 500 1000 1500 2000 2500

h/100 lb)

2012 AHRI Data – Increase Capacity

(7.6 – 5.8) / 7.6 = 24% Reduction

0 500 1000 1500 2000 2500

h/100 lb)

2012 AHRI Data – Best In Class

(7.6 – 5.0) / 7.6 = 34% Reduction

0 500 1000 1500 2000

Ice Harvest Rate (lb/d)

All Air-Cooled Models

CEE Tier I Air-Cooled Models

2005 AHRI DatabaseObservation #3:

For a given capacity of air-cooled

machine, water use varies dramatically

18 to 38

2014 AHRI Database

18 to 26

(38 – 26) / 38 = 32% Reduction

Energy and Water Wise:

We are headed in

the right direction!

Perspective on

Water-Cooled Machines

Condenser cooling water dwarfs potable water use!

750 gal = 500 lb

$2,900 a year!

quick condenser water calc

Big Lesson:

Specifying an

energy and water efficient

ice machine will save money

How Much?

Our Restaurant has:

• 1 gas fryer

• 1 gas convection oven

• 1 solid-door reach-in refrigerator

• 1 gas griddle

• 1 700 LB ice machine

600 lb/day harvest

1651 1964

556 820

2207 2784

How to Find Efficient Ice

Machines

Calculate the Savings

Here’s where you find

efficient equipment

www.energystar.gov/cfs

www.fishnick.com

The F.S.T.C Modeling Method

1. Find the appliance energy information

2. Simulate the appliance energy usage

3. Transfer the info to a spreadsheet

4. Compare the efficient appliance to

the baseline appliance

http://www.ahridirectory.org/ahriDirectory/pages/home.aspx

AHRI Directory of Certified Product Performance

ACIM – Automatic Commercial Ice-Makers* and Ice Storage Bins

* Changed from “Ice-Cube Machines” to now include continuous-type machines.

Simulate

How to Calculate Savings?

Start at www.fishnick.com

www.fishnick.com/saveenergy/tools/calculators/

Transfer

12345671234567

fryer 1 annual energy cost

baseline 100

actual design 75

dollar savings 25$

percent difference 25%

Compare

fryer 1 annual energy cost

baseline 100

actual design 75

dollar savings 25$

fryer 2

baseline 100

actual design 70

dollar savings 30$

Our Example Ice Machine

Decisions, Decisions...

1. base efficiency water cooled

2. base efficiency air cooled

3. high efficiency air cooled

4. high efficiency upsized air cooled

5. highest efficiency upsized air cooled

6. highest efficiency flake

30 Minute Break

Resume at 11:15

If you are not able to

attend Part Two:

Please fill out the

RFMA evaluation

Part Two:

Load Shifting Ice Machines

www.fishnick.com/handouts/02182014

Download Today’s Handouts:

But First...

Peak, Partial Peak, and Off Peak

Energy (kWh) Prices Vary

Maximum Demand – Any time of Day

Maximum Peak Demand – Noon to 6 PM

Maximum Part‐Peak Demand9 to Noon & 6 to 9 PM

Demand (kW) represents how much

generation capacity the utility has

to reserve on your behalf

Summary: Ways You Pay

• Energy Charges (kWh)

– Peak

– Part-Peak

– Off Peak

• Demand Charges (kW)

– Max Demand

– Max Peak Demand

– Max Part-Peak Demand

(No Peak Demand in Winter)

The Problem with Ice Machines

We run them when electricity is expensive.

They are off when electricity is cheap.

What is “Load Shifting” an Ice Machine

Running an ice machine off the utility-peak period,

and through the night to produce ice for the

next day.

Potential Savings

1. Buying cheaper off-peak energy (kWh)

2. Reducing max and peak demand charges (kW)

Other Potential Benefits

1. Less heat in the kitchen (load on the AC)

2. More efficient operation (lower ambient)

3. Quieter kitchen (off during production)

Is this Possible...

Let’s Investigate

Ice Machine Field Study #1

• How does the AHRI database relate to the real world?

• How much water (and energy) do they really use?

• How much ice do machines typically produce in different

types of operations (duty cycle)?

• What do typical load profiles look like?

www.fishnick.com/publications/appliancereports/special/Ice-cube_machine_field_study.pdf

Ice Machine #1 - Typical Day Profile

6 AM 9 AM 12 PM 3 PM 6 PM 9 PM 12 AM 3 AM 6 AM

Electric Water

Ice Machine Field Study

Avg. Duty Cycle = 48%Max. Duty Cycle = 61%Load Shift: YES

1060 lb/24 hr

Electric 1 Electric 2 Water

1130 lb/24 hr x 2

Avg. Duty Cycle = 60%Max. Duty Cycle = 91%Load Shift: Maybe

Electricity Water

1130 lb/24 hr

Electric Water

340 lb/24 hr

Electric Water

Avg. Duty Cycle = 83%Max. Duty Cycle = 100%Load Shift: No

275 lb/24 hr

Electric Water

Avg. Duty Cycle = 87%Max. Duty Cycle = 100%Load Shift: No

830 lb/24 hr

Electric Water

440 lb/24 hr

Electric Water

1130 lb/24 hr

Important Number:

A machine with a 60% to 65%

duty cycle is a good candidate for

load shifting

Load Shifting Example

• Full-service restaurant, open

for lunch and dinner.

• Two air-cooled ice machine heads

with remote condensers on top

of one bin.

• AHRI listed Ice Harvest Rate –

1,130(x2) lb/24hr

• AHRI listed 4.6 kWh/100lb

• Average Duty Cycle = 50%

• Peak Duty Cycle = 65%

Daily Ice Machine Usage Profile

On-Peak Demand Period (Summer)

California Utility Rate Information• E-19 (Non-FTA Rates) Offers demand-metered time-of-use (TOU) service.

Customers likely to benefit have high electric use and high load factors and are able to use significant percentages of their electricity during the off-peak period. There are optional (E19V, E19 X and E19W) versions below 500 kW as well as E19 mandatory which applies to accounts with demands between 500 and 1,000 kW. See tariff for rate limiter, power factor, nonfirm.

• Meter charge: =$4.11992/day for E19 V or X; =$3.97799/day for E19W2/; =$13.55236/day for E19S mandatory; =$19.71253/day for E19P mandatory; =$39.42505/day for E19T mandatory

Summer

On Peak $13.17

Summer

On Peak $0.15463

Part Peak $3.02 Part Peak $0.10708

Maximum $7.97 Off Peak $0.08766

WinterPart Peak $1.15

WinterPart Peak $0.09577

Maximum $7.97 Off Peak $0.08480

Source: http://www.pge.com/tariffs/tm2/pdf/ELEC_SCHEDS_E‐19.pdf

Restaurants historically set their max peak during the on‐peak period for an effective demand charge of $21/kW on 5 kW > $100 per month.

Energy Consumption SavingsSummer Season Normal Shifted Winter Season Normal Shifted

Days 183 183 Days 182 182

Power (kW) 4.83 4.83 Power (kW) 4.83 4.83

On‐Peak (hr/day) 6 0 On‐Peak (hr/day) N/A N/A

Part‐Peak (hr/day) 5.5 1 Part‐Peak (hr/day) 11.5 1.5

Off‐Peak (hr/day) 0.5 11 Off‐Peak (hr/day) 0.5 10.5

On‐Peak Cost $560 $0 On‐Peak Cost N/A N/A

Part‐Peak Cost $356 $97 Part‐Peak Cost $665 $87

Off‐Peak Cost $311 $840 Off‐Peak Cost $316 $828

Total Summer Costs $1,227 $937 Total Winter Costs $981 $915

Summer Cost Savings $290 Winter Cost Savings $66

Total Annual Costs $2,207 $1,852

Annual Cost Savings $355

Demand Charges SavingsSummer Season Normal Shifted Winter Season Normal Shifted

Days 183 183 Days 182 182

Power (kW) 4.83 4.83 Power (kW) 4.83 4.83

On‐Peak Charge $64 $0 On‐Peak Charge N/A N/A

Part‐Peak Charge $15 $15 Part‐Peak Charge $6 $6

Maximum‐Peak Charge $39 $0 Maximum‐Peak Charge $39 $0

Total Summer Costs $700 $90 Total Winter Costs $264 $36

Summer Cost Savings $610 Winter Cost Savings $228

Total Annual Cost $965 $126

Annual Cost Savings $839

Savings Potential

• By moving the operation of the ice machine to mostly off-peak periods the energy cost savings would be $355.

• The Demand Charge savings would be an additional $839.

• Using a simple time clock to delay the operation of the ice machine this restaurant would see an annual savings of $1194.

38% Reduction in energy and demand charges

Important Note on Demand Savings:

If the max demand happens at some

time other than peak hours, you may

not get the full demand savings.

Without more detailed info: You can

only truly count on energy savings.

What about savings from

upgrading the machines?

Potential Annual Energy Saving with High Efficiency Replacement Machine

2,0262,306

#1 #2 #3 #4 #5 #6 #7 #8

$1,200

Potential Annual Water Saving with Low Water Use Rate Replacement Machine

#1 #2 #3 #4 #5 #6 #7 #8

$1,000

$1,250

$1,500

water-cooled

Ice Machine Field Study #2Energy and Water Saving

with Ice Machine Upgrade and Load Shifting

Food Service Technology Center

September 2011

fishnick.com/publications/fieldstudies/

Average Cycle Power Reduction (kW) -- 0.16 Energy Saving (kWh/100 lb) -- 2.20 Energy Percentage Savin g -- 33.6% Annual Energy Saving (kWh) -- 1,580 Annual Energy Cost Saving -- $284 Water Saving (gal/100 lb) -- 4.0 Water Percentage Saving -- 13.8% Annual Water Saving (gal) -- 2,840 Annual Water Cost Saving -- $19 Annual Energy and Water Cost Saving -- $303 Peak Demand Reduction (kW) 8 -- 1.05

The Bottom Line

$500 total annual savings

Ice Machine Field Study #3

Look for it on fishnick.com soon

True Burger, OaklandIce Machine – Calculated Energy Use

Old Ice Machine NewMachine

Rate Capacity (lb/24h) 155 410

Rated Energy Use(kWh/100 lb ice)

9.90 5.73

Duty Cycle (%) 86 29

Annual Energy Use Savings (kWh) ‐ 1,400

Demand Reduction (kW) ‐ 1.0

39% Reduction in energy charges

TrueburgerCost Savings:

Bridges Restaurant, Danville CA Ice Machine – Calculated Energy Use

Old Ice Machine NewMachine

Rate Capacity (lb/24 h) 751 1,180

Rated Energy Use(kWh/100 lb/ice)

6.6 4.62

Normalized Duty Cycle (%) 81 52

Annual Energy Savings (kWh) ‐ 4,986

On‐Peak Reduction (kW) ‐ 2.2

Savings at Bridges:

New machine + upsizing + load shifting =

40% reduction in energy (kWh) costs

But, no demand (kW) charge savings

This is the safest formula for savings

at present

Ice Level at 12:00 PM

Important Note on Operations:

Empty the bin as early as possible in

the morning so the machine can

refill until noon

Important Note on Controls:

The best method to control the

machine is to hardwire the timer into

the bin switch.

That way if the ice cycle begins, the

machine does not turn off before harvest.

Then set the timer to cut off about

15 minutes before noon.

How do you know if your ice

machine is a candidate?

Monitor the machine and

determine the duty cycle

Couple of final thoughts:

Potential Issues with Upsizing?

• Space considerations?

• additional heat load to space if upsizing

without remote?

• existing breaker capacity?

Load Shifting Challenges?

• Ice storage bin is not large enough and ice

runs out during the day (or perceived to run

• possible complaint reaching ice on the

bottom of the bin?

• (First-in/first-out design is possible solution)

• Time clock failure defeats benefit

The Future?

“In the foreseeable future, it is conceivable that ice making in all restaurants will be during non–peak utility periods, and in many cases, during the off-peak, cooler hours of the night.”

Don Fisher

Lunchtime!!

FEBRUARY 16, 2014

Give Us Your Feedback!

presentation by: richard young

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