Which Intelli-Hood is in My Facility? How to Identify Intelli-Hood Systems

How can a facility manager identify Intelli-Hood systems at his or her various properties? Different systems may be installed, and each system has its own unique reference guide and troubleshooting tips.

Background

Over the years, Melink Corporation has designed and implemented three Intelli-Hood® systems: IH1, IH2 and IH3. Each system has its own specific configurations. While all work on the same basic principles, they DO NOT have the same parts or interfaces.

So how can you determine which system is in your facility? You can determine this by physical attributes and the system’s serial number. Watch our how-to video and consult the steps below…

How to Identify Intelli-Hood Systems

There are three methods to identify your Intelli-Hood system:

Serial Number

The serial number is the absolute best way to identify your system version. On the inside of the system’s panel door, you will see the unit’s serial number. The color of the label may vary, depending on your system. IH1 normally has a white label, whereas IH2 and IH3 have blue labels.

As for the numbers themselves, IH1 systems began with serial V1000 or V001000 and continued until the late V3999 numbers. IH2 serial numbers started at V4000 or V004000 and counted up from there.

Identifying your Intelli-Hood System by IH1 and IH2 serial numbers

At the beginning of IH3 we changed the starting point slightly and began with V300000. All serial numbers in the V300000 and V400000 are IH3.

Identifying your Intelli-Hood System by IH3 serial numbers
Cable Colors

Cable colors are different among systems. If your system has white/grey cables, it is an IH1. If your system has blue cables, it is IH2. Green cables signal IH3.

Touchpads

The main touchpad on the kitchen hood can distinguish your system.

IH1 has a single digit “HOOD” display.

Intelli-Hood IH1 display

IH2 has a four-digit “HOOD” display.

Intelli-Hood IH2 display

IH3 is our first system with a full LCD display.

Intelli-Hood IH3 display

Knowing Your System

To accurately troubleshoot system issues and to order replacement parts, you must supply the Melink Technical Team with your system model (IH1, IH2 or IH3). Most issues can be solved over the phone with a facility manager and/or contractor capable of performing the work on site.

If you are purchasing replacement parts and you are not on site, please verify the system model with the site beforehand. If the system model cannot be verified, Melink cannot guarantee the replacement parts are correct. There is a restocking fee for parts ordered in error.

If you cannot determine which system you have, Melink Corp does maintain an internal database. However, we cannot guarantee your facility is in the database. Frequently, restaurant sites change ownership and names. For instance, what was once “Joe’s BBQ” may now be known as “Bob’s BBQ.” If no one has contacted Melink to update the original site name, it will not be searchable in the database.

Access Intelli-Hood reference materialsFAQs, and how-to videos. For advanced troubleshooting, contact Melink Technical Support (available 24 hours a day, 7 days a week) via web request or by calling 877-477-4190.

Intelli-Hood System Basics: Using the Touchpad

The Intelli-Hood® touchpad is the primary user interface of the system. Every Intelli-Hood is equipped with at least one touchpad; some systems have multiple touchpads. Touchpads vary by system model; consult this guide for help determining your system. In this post, we will focus on the IH3 touchpad.

IH3 Touchpad Navigation

Fans Button: The Fans Button is typically used to change the state of the system between “Standby Mode” (exhaust fans off) and “Energy Saving Mode” (exhaust fans running).

Lights Button: This turns the lights of the hood on and off. This function is optional and may not be used in all applications of Intelli‐Hood. Consult the design documents for your system to determine if this button is used.

Soft-Key Buttons: Two soft-key buttons below the display screen can be used to navigate functions displayed on the screen. In normal operation modes, the right button is used to access programming and help menus, and the left button is used to active the “100% Fan Speed Mode.” These functions vary when the user is navigating the program settings.

Arrow Buttons: The two arrow buttons are used to scroll through configuration parameters and can be used to change programming values.

Status Screen: The status screen shows the operational state of the Intelli‐Hood system.

Faults Screen: The faults screen shows active system faults that need addressed. Once a fault is cleared, it will no longer be displayed here.

IH3 System Modes

In Standby Mode, the fans will be off and users will see the Intelli‐Hood logo splashscreen. The right soft key can be used to enter the menu.

In Energy Saving Mode, at least one fan associated to the touchpad is in Energy Saving Mode. This may not pertain to all fans. The display will scroll through the hoods and fans that are active and display their respective operating speeds. The left soft key can be used to send the system to 100% or Bypass Mode, and the right soft key can be used to enter the menu.

In 100% or Bypass Mode, the display will scroll through the hoods and fans and display their respective operating speeds. The left soft key can be used to send the system into “Normal” Energy Saving Mode, and the right soft key can be used to enter menus.

In the Menus Home Screen, the user can locate System Status, System Configuration, the Help Menu, and the About Menu.

Intelli-Hood touchpad menu navigation

IH3 Menus

System Configuration Menu: This is where the system can be configured by adjusting the number of hoods, fans, and many other parameters. The System Configuration Menu will be locked with a specific pass-code in order to prevent accidental modification of system parameters. Users should not attempt to modify the configuration without the help of a certified Intelli-Hood professional.

Help Menu: The Help Menu contains instructions for how to contact your local rep or the manufacturer for technical support and other information.

About Menu: The About Menu simply provides system information such as the firmware version, serial number, IP address, date, and time.

Intelli-Hood Touchpad Maintenance

Most damage to the keypad is related to cleaning. Do not clean the touchpad with any harsh or abrasive chemicals. If the surface needs to be cleaned, use a mild dish detergent like Dawn dishsoap. If holes start to wear in the touchpad, contact Melink for parts to replace the labels or the touchpad itself. This is to avoid the internal parts from getting wet, potentially leading to kitchen downtime.

Intelli-Hood Touchpad Troubleshooting

If your touchpad screen is frozen, the system has most likely “lost” its configuration. Contact Melink Technical Support so that the appropriate configuration can be reloaded. 

If your touchpad is frozen and it is not a configuration issue, you may want to verify that the LEDs on the circuit board are illuminated.  Power the system down at the controller and pull the cell battery off the baseboard, replace the battery, and turn the system back-on.

Access Intelli-Hood reference materials, FAQs, and how-to videos. For advanced troubleshooting, contact Melink Technical Support (available 24 hours a day, 7 days a week) via web request or by calling 877-477-4190.

Intelli-Hood System Basics: Operational Modes

There are four Intelli-Hood® system operational modes: Energy Saving, Standby, 100% (Bypass), and Emergency Fire. The Intelli­-Hood HVAC controls package visually monitors the level of cooking activity and automatically instructs the exhaust fan to operate only as fast as necessary to save energy. Learn the basics about each operational mode…

Energy Saving Mode

First, Energy Saving Mode is the operational state when one or more exhaust fans are on. In most cases, all exhaust fans controlled by Intelli-Hood will be in Energy Saving Mode at the same time. However, in some configurations, it is possible that some fans will be in Energy Saving Mode while others remain in Standby.

Standby Mode

In Standby, the exhaust fans are not operating, but Intelli-Hood is monitoring temperature and optic sensors.  The system’s touchpad is typically used to manually change the mode of the system between Standby and Energy Saving Mode. Depending on both cooking conditions and pre-programmed settings, it is possible for Intelli-Hood to automatically change modes.

100% Mode (Bypass Mode)

Next is 100% Mode, which is commonly referred to as Bypass Mode. This mode is a secondary function. Typically, Intelli-Hood is set to appropriately send the exhaust fans to full speed based on conditions detected by temperature and optic sensors.  Kitchen staff has the ability to send fans to full speed by placing the system into 100% Mode when it is operating in Energy Saving Mode. 100% Mode is a timed function with a default expiration time of ten minutes.  After the timer expires, fans will revert back to Energy Saving Mode.

Emergency Fire Mode

Lastly, the Emergency Fire Mode is triggered by the fire suppression system. This mode is activated when the main power to the Intelli-Hood is removed. In this mode, the touchpad and sensors will have no power or function.

Access Intelli-Hood reference materials, FAQs, and how-to videos. For advanced troubleshooting, contact Melink Technical Support (available 24 hours a day, 7 days a week) via web request or by calling 877-477-4190.

The Advantages of Optical Sensing in Demand Control Kitchen Ventilation Systems

As the inventors of demand control kitchen ventilation for commercial kitchen systems over 25 years ago, Melink is solely focused on providing maximum energy savings with safe and reliable controls for our customers with our Intelli-Hood® system. Not surprisingly, we’ve learned a lot of things over these years and continuously improve our controls based on lessons learned, industry trends, best practices, technological advances, laboratory and field research. Our industry leader status makes us a ripe target for competitors and naysayers, to which we welcome and enjoy engaging in a healthy debate to advance the usage of demand control kitchen ventilation across the globe.  To this end, I would like to address a document produced by a manufacturer and a respected goliath in the kitchen ventilation industry. 

*All text in red is directly taken from a Captive-Aire produced document obtained by Melink*

The Captive-Aire Demand Control Kitchen Ventilation (DCKV) system controls the fan speeds based on heat generated from the cooking appliances in comparison to the room temperature. Captive-Aire has done extensive research into the effectiveness and practicality of sensing smoke to override the system and turn on the fans. Melink offers an optic sensor inside the hood, which, if penetrated by smoke, will automatically turn the fans to high speed. This is one of the primary differences between Melink and DCKV. 

Melink has performed extensive research over the years into various sensing methods, including space temperate versus hood canopy sensing (delta T) methods, and fallacies discovered in the delta T method is what led us to the patent for utilizing optical sensors in conjunction with heat sensing. Our research uncovered many external factors in the kitchen environment that caused false readings including cross drafts, supply air configurations, door openings and seasonal temperature changes that could trick the system into a cooking response and eliminate energy savings.

Another challenge in the temperature only approach is determining the level of cooking based on these temperature changes alone as the cooking effluent (smoke, steam, etc) often presents itself before a strong thermal plume on the temperature sensor. For example, if you place a cold hamburger patty on a grill the temperature will initially reduce as the heat transfers into the food while creating effluent that must be captured by the hood.  Systems reliant upon temperature only are slow to react to this change and you are left with two options; decrease the temperature range of the system so it runs full speed at the slightest presence of heat (diminishing any energy savings), OR don’t effectively capture the effluent in the hood canopy and cause smoke rollout.  As we at Melink like to say, “You can’t capture what you can’t see.” 

We have found that using an optic sensor to sense smoke is very problematic. When installed inside a greasy exhaust hood, the lens will tend to get caked with grease. This will cause the fans to run at full speed all the time, and therefore eliminate your energy savings. As a result, Melink installs small fans to continuously blow air at the lens to try and avoid grease particles from landing there. This is another component the needs to be maintained and serviced regularly. These optic lenses also require an I/O processor to be wired into the system—this is one more component. If anything happens to the lens, fan, or processor the system will fail. This results in a sustainability issue. Electrical components inside a greasy exhaust hood may not be a sustainable option over the course of several years. The optic sensors/lenses need to be cleaned, and according to the Melink manual, should not be sprayed with hot water or steam by the hood cleaner to avoid damage.

 Yes, our system has a brain and it’s called the System Controller (formerly I/O Processor referenced). All demand control kitchen ventilation systems have some sort of controller to interpret the signals coming in and we like to think our brain is pretty special.  In fact, unlike most competitor systems that utilize an off the shelf PLC controller we custom design ours for the sole purpose of saving you energy in the kitchen and integrating into your building.  Our System Controller is native BACnet (IP), internet ready, 4G wireless capable and has the brainpower to control up to (39) kitchen hoods and (64) exhaust or supply fans. 

We do utilize a component called the Air Purge Unit (APU) that contains a 12VDC fan to direct airflow into the optic housing to maintain a positive pressure environment to alleviate grease buildup.  However, kitchens can be harsh environments and depending on the appliance type underneath these could benefit from a monthly swipe with a clean cloth if it’s above a high grease producing appliance, but less intensive appliances mean less cleaning.  Fortunately, we use that big brain of ours to automatically re-calibrate the optics every day based on cleanliness for optimal performance and if it gets too dirty the system will alert you via the Touchpad or email as to which hood may need cleaned.  

Additionally, a typical Melink system costs much more than a Captive-Aire DCKV so the payback period for a Melink system is much longer.

Not necessarily, the formula for the simple payback period is the initial project cost divided by the annual savings to determine at what time the investment breaks even. If a more intelligent system can save 3x the energy of temp-only system, then the simple payback periods are equal. The downside of this metric is the failure to account for the time value of money and consideration of cash inflows beyond the payback period.  It’s important to look past first cost and take into account the full savings yielded over the life of the system and perform life cycle cost analysis. 

For example:

        Temp-Only System

  • First Cost = $5,000
  • Annual Savings = $1,500
  • Simple Payback Period = 3.3 Years
  • Energy Savings over (7) Years = $10,500
  • Net Savings: $10,500 – $5,000 = $5,50

Melink Intelli-Hood®

  • First Cost = $15,000
  • Annual Savings = $4,500
  • Simple Payback Period = 3.3 Years
  • Energy Savings over (7) Years = $31,500
  • Net Savings: $31,500 – $15,000 = $16,500

Over the life of the systems in this example Intelli-Hood® will yield $21,000 in more energy savings vs. the competitor, less the initial capital difference of $10,000 ($15,000 – $5,000) = $11,000 more in
free cash flow.  This example does not factor in the time value of money.   

The below data shows the savings difference when a Melink Intelli-Hood® system was installed at a restaurant previously using a temperature only system. The baseline data was provided to the owner by the temp-only hood manufacturer, and we analyzed the electrical and conditioned air savings via our Estimated Savings Report.  Once the Intelli-Hood® system was installed we compared the data and found that Intelli-Hood® system yielded 523% more savings than the previous system. Click here to see real IH performance results.

 

Testing has shown that very sensitive heat sensors are as effective as optic sensors in triggering exhaust fans if heat or smoke is present. If cooking generates smoke, then the cooking process will also generate heat. The heat sensors in the Captive-Aire Demand Control Kitchen Ventilation are easily adjustable as different project and applications may require.

Through our own testing in the lab environment, and more importantly the lab of reality in the commercial kitchen with over 10,000 systems, temperature sensing alone will not allow for a quick response to smoke. Based on our data obtained from an installed temp-only system, the heat sensors appeared to provide no active modulation and acted basically as a two-speed system with an active base speed of 80% and quickly ramping a holding a constant speed of 100% through the day since the appliances were on. Again, without the ability to visually monitor the cooking a temp-only system must be run at much higher minimum speeds as a safety net for capturing effluent. This is a major energy savings penalty.

The heat sensors may be “easily adjustable”; however, this requires human manipulation and functional commissioning.  Most often these systems are sent to a mechanical contractor with the instruction to connect the temperature probes to control panel and are left at whatever the default factory setting is.  We like humans too but given the chance we like to engineer around potential issues and lack of consistency from one contractor to the next around the world.  Thus, we patented another feature dubbed “Auto-Temp Span”, which collects performance data from every sensor in the system at defined intervals and automatically sets the optimal temperature spans for every hood in the system.  If the chef decides to change menus, appliances, or a new tenant takes over the space the system will learn these new habits and self-commission for optimal performance.  Call it “machine learning”, call it “artificial intelligence”, we call it a good idea that benefits the end-user.

Lastly, the DCKV has a 100% air override button to send the fans into full speed as a safety precaution.

This override button feature is a code requirement for all demand control kitchen ventilation systems; we have one too.

Here are a few additional differences between Captive-Aire DCKV and Melink Intelli-Hood®:

  • Captive-Aire DCKV is typically programmed with a “prep mode” feature to allow greater energy savings. This feature will run the exhaust fans at a very low speed
    (typically, 20% speed) when the system is first turned on by staff or BAS. This speed is equal to the design differential between exhaust and make-up air. DCKV will run in prep mode until the heat of the appliances necessitates greater exhaust at which point the exhaust and make-up air will both ramp up and cooking mode will commence.
    Melink as currently designed runs both make-up air and exhaust at 50% of its design. 
  • In cooking mode, Captive-Aire designs for a 20% reduction in fan speed during light load cooking times. This reduction is based on extensive research on the topic. Lab testing by The Food Service Technology Center in California has shown that no more than a 20% reduction from a proper design cfm can be made in order to allow the
    system to adequately exhaust appliances when in light load. The Melink system allows for a 50% turndown, therefore, in order for that amount of
    reduction to work properly, the design cfm would have to be increased so the system still works effectively at a 50% reduction. A lower design cfm with 20% fan speed reduction will be more efficient and save more energy than a higher design cfm with 50% fan speed reduction. Captive-Aire DCKV has the ability to provide a 50% turndown, but we do not recommend this. 

From our perspective, this represents nearly a three-speed system with “modes” to make up for the lack of technology, sensors, programming, and algorithms to modulate based on real-time cooking information and optical monitoring, resulting in a loss of energy savings ability. As representative in our data, the temperature spans are typically set so low with these systems, that as soon as any appliances are on, the fans run at an 80% minimum for a very short amount of time and then jump right to 100%.  Unfortunately, it’s pretty rare to see any appliance gas valve regulation in commercial kitchens and most appliances are left at nearly full temperature all day independent of actual cooking, which causes temp-only systems to run at or near full speed all day. We’ve also come across several temp-only systems in the field running at 100% speed when the exhaust temperature read 72 and 73 degrees Fahrenheit.

The Melink Intelli-Hood® system is capable of 20-30% minimum speeds as well, but turn-down ratio is a moot point when the rubber meets the road, or when the meat hits the grill in this case.  Our default minimum speed is 30%, a 2% electrical energy difference vs 20%, and we actively modulate through the entire speed spectrum to 100% to maximize energy savings.  The key to electrical energy savings in motor applications lies in the Law of Affinity (below), which at the top of the fan curve roughly translates to a 10% speed reduction = 25% electrical energy
savings. The key to savings with demand control kitchen ventilation is having the optics to safely and actively modulate at the upper ends of the spectrum during the cooking day to maximize savings near the top of the fan curve between 70-100%.

 

In addition to electrical energy savings from the motor control, Intelli-Hood® also integrates into the make-up air system to modulate based on the exhaust demand.  This modulation provides additional conditioned air savings and can have a significant impact on the payback of the system.  The more extreme the outdoor air environment, the greater the opportunity for energy savings in the reduction of the heating or cooling loads.  The ratio of savings for conditioned air is 1:1 with fan speed reduction, i.e., a 30% reduction in speeds = 30% reduction in conditioned air.

With nearly 20 states adopting ASHRAE 90.1 2010, or higher, energy standards it’s clear that demand control kitchen ventilation is here to stay and we’re proud to have launched this revolution back in 1989.  One of our core values at Melink is Innovation, and we continue day in and day out to develop more advanced commercial kitchen control systems to save our customers valuable money and hopefully make the planet better for our future generations one hood at a time.  Feel free to contact us regarding your next kitchen design involving demand control ventilation or if you’re an existing operator of a commercial kitchen looking to save money, we happen to be experts in retrofits as well.

Determining if DCKV is Right for You?

When a customer is first debating if Demand Control Kitchen Ventilation (DCKV) is right for their facility, there are multiple questions that come to mind. What is a good application for DCKV? What does it cost versus the lifetime payback? Does it actually slow fans down that much? What is the ability for service in the future?

All of these are valid questions. The most important thing is to partner with a company that works with your team to evaluate and determine what solution is best at the onset of reviewing the opportunity. In order to answer the above questions, the DCKV provider should be asking you the following at minimum:

  • What is the size of the hood(s) (Length X Width)?
  • What is the schedule of the exhaust fans, do they only run 8hrs/day, 12hrs, 24hrs?
  • What kind of equipment is underneath the hoods?
  • What are current utility rates for your area of the country?
  • Is there dedicated supply air to the kitchen space?

With this information the DCKV Manufacturer should be able to provide some advice.

What is a good application?

Four primary factors play a role in this answer. They include: utility rates, total fan horsepower (Exhaust + Supply), exhaust fan run hours and your geographic location.

The total horsepower is self-explanatory. The greater the HP the larger available savings. However, lower horsepower may not disqualify an application. If there is a total of 5hp between exhaust and supply, operating longer than 12hrs/day, with moderate utility rates of at least $0.08/kWh, DCKV systems can be a feasible savings opportunity.

Fan operating hours additionally play a role based on the savings, the longer the operations the greater savings. This type of savings can be compounded depending on the geographic location as significant conditioned air savings can be recognized. 

What does it a system cost versus the lifetime payback?

The cost of a system will vary based on the complexity as well as the selected technology. Two options are a temp only based system or one that incorporates additional optic sensors. Although a temp only based system may cost less, it is important to evaluate savings over the lifetime of equipment compared to a system that incorporates optics.

Assume a 12-year life cycle of equipment. For the sake of this discussion, we will evaluate the following scenario:

  • Single Hood (20ft long)                  –   24hr Fan Operation
  • 5hp Exhaust (5000cfm)                  –   $0.10kWh
  • 3hp Supply                                          –   $1.02therm
Cost Avg. Run Speed Annual Savings Simple Payback Lifetime Savings (12yrs)
Temp – Only $7,000 80.5% $3,502 2.0 yrs $42,024
Optics Based System $16,000 58% $7,865 2.0 yrs $94,380

As seen above the lifetime savings of an optic based system is greater than twice the amount of a temp-only based system. It is important for a DCKV partner to offer a solution best for the customer’s needs, perhaps a blended system would provide the largest amount of savings. For example, perhaps on a larger kitchen, there is significant savings opportunities for one or two of the hoods. However, another single hood has only a single pizza oven underneath, this is when it is important to partner with a manufacturer who has technologies that will maximize savings, such as auto-temp spans and scalability of their system.

Does it actually slow fans down that much?

In the savings example above there is a significant disparity between the average runs speeds of a Temp Only based system and that of a system including optics. When reviewing and selecting a DCKV system, it is important to have proven data of performance. Look for manufacturers that have case studies for their technologies, and significant volumes of measurement and verification. Every market sector is different regarding a 24hr average run speed. As a buyer do not hesitate to ask for examples of performance for your market being evaluated. You can also utilize third party publications such as Demand Ventilation in Commercial Kitchens An Emerging Technology Case Study, written by Fisher Nickel, Inc found here.

What is the ability for service this in the future?

One final important aspect to consider is what happens post installation. Commitment from a manufacturer to service over the lifetime of a system is very important. Does your DCKV partner go beyond the standard warranty? Certain manufacturers offer 24hr engineering technical service. Do they have a service network of technicians available to visit your site if needed? Another consideration is where would replacement parts be purchased from. Some manufacturers have components manufactured outside the United States which can delay delivery and in return create a headache for you to provide consistent service to your customers.

Another important focus on the future would be, what is the adaptability of the system? Everyone has seen a kitchen space eventually be remodeled and cooking equipment is swapped out for a new concept. Perhaps there is increased heat from this equipment change, so can the originally selected system adapt to this change? Certain manufacturers have temperature probes that area initially calibrated at startup based on initial equipment. On the other hand, Melink Corporation’s Intelli-Hood, offers an Auto-Temp span, that self-calibrates, and spans based on trends of continuous data points and monitoring therefore, an equipment change resulting in an increase or decrease in heat load will be recognized and self-adjusted for maximum savings.

How to decide what works for you.

In closing, there are many important variables to consider when selecting a product including DCKV. To some, upfront cost is a primary concern, and to many other end users the most important may be what happens over the life of the system. “Will the manufacturer provide me support?” and more importantly “How much will this save me over time?” Many of us are always saving for our retirement, perhaps now is the time to invest in the savings that are available within your kitchen. Personally, I would love to save double that over a lifetime of a system for a product with the same initial payback.

“We’ve Done Benchmarking. We’ve Done Lighting. What’s Next?!” Kitchen Ventilation.

The Benefits of DCKV

Kitchen ventilation, both exhaust and make up air, represent a significant opportunity for kWh and kBTU reductions in your facility. Demand Control Kitchen Ventilation, (DCKV) uses temperature and optic sensors to vary exhaust speed and make up air fans.  This is in response to precise cooking intensity underneath all kitchen hoods. With fans only running as needed, savings are gained on fan energy (controls produce 40-60% average fan speed versus 100% without controls). In addition, there are heating and cooling savings gained as a result of kitchens not evacuating all air that was just conditioned.

These controls can be installed in new construction projects. They’re usually specified by engineering firms in the design phase of your project, and should qualify for one LEED point. In addition, DCKV is a path to compliance for commercial buildings’ energy codes for states that have adopted ASHRAE 90.1 2010 and greater. You can see what your state’s requirements are here.

Retrofitting

Retrofitting the temperature and optic controls within existing kitchen exhaust hoods is equally effective at generating energy savings. It’s important to confirm that the controls are UL 710 and 2017 listed. This permits them to be installed in any manufacturer’s hood in any cooking application. There are many utility rebate incentive programs available for the installation of DCKV as well.

Kitchen Ventilation in Action

The financial impact for hospitals’ operating costs is significant when kitchen exhaust and makeup air fans no longer run at full speed 24/7.  A study by the EPA demonstrated that each dollar saved by a non-profit hospital, is the same as generating $20 in new revenues. Incidentally that same dollar saved in a for-profit facility is like increasing EPS by one penny.

Melink recently completed a Mid-West hospital project that produced $20,000 (per year) in combined savings. The savings included electrical, heating and cooling costs. Using EPA study metrics, this equivalates to $400,000 in new revenue for this facility.  Taking rebate incentives for our technology, the hospital’s ROI was less than one year.

The Purpose of DCKV

The goal of any DCKV project is to install controls that maximize the energy savings within the kitchen. In addition, DCKV will assist compliance with building energy codes, attain LEED points and make kitchens quieter and more comfortable. This article goes into greater detail and dives deeper into how these controls pay back initial investment. The articles recently appeared in the American Society for Healthcare Engineering publication, Inside ASHE.

Find the Inside ASHE article on kitchen ventilation here.

Energy Conservation in Commercial Buildings

There’s no doubt that energy conservation in commercial buildings (or any building for that matter) is important.  Reducing operating costs are important for valuations, freeing capital up for other projects or simply reducing the carbon footprint of your building, or portfolio of buildings.  There are many different ECMs (energy conservation measures) available to companies to help achieve these goals, and almost always the decision to use certain measures comes down to “I have to be at 3 years or less for the simple payback”.   While financial metrics are important, I believe that this focus often obscures the soft benefits to the building’s occupants and workers.

 A noise study was recently completed where a corporate kitchen’s noise levels were measured before and after the installation of variable speed controls on both the hood exhaust and supply fans. Traditionally kitchen exhaust fans run at 100% speed for constant periods of time.  With the addition of a variable speed system, like Melink Intelli-Hood, fan speeds are reduced to slower speeds when cooking isn’t at its maximum.  From an energy savings perspective there are two buckets of operational cost reductions, fan energy and conditioned air.  The chart below shows that when the kitchen fans are operating at 100% speeds the decibel level is just short of what a fire alarm sounds like when activated.  With the addition of the variable speed controls, the site realized much lower average fan speeds, as well as a reduction in kitchen noise levels to just below conversational speech, or a reduction of 11 decibels. 

The financial metrics for this project met all approval hurdles and the site is very happy.  For a moment, think about the Chef and his staff.  Their work environment has now become much more quiet.  They can hear each other better when they’re coordinating and preparing meals for several hundred employees each day.  Shouting and miscommunication is greatly reduced, and their environment is more pleasant.  This particular improvement would be hard to show on an income statement…or would it? 

As one example, within Seniors Housing, Dining Services is consistently near, or at, the top in employee turnover percentages.  The current industry turnover rate is 36.91%, (McKnight’s Senior Living, Salaries and Benefits Report 2017-2018) with Certified Nurses Aids coming in a close second at 34%.  It will cost a facility approximately $2,500 in recruiting and training to backfill a single new employee.  Compound that amount with multiple hires each year and it gets expensive very quickly.  If along with reducing energy costs a site can also create a better work environment for its full time employees (FTE), then perhaps that large expense can begin to be reduced and more employees will remain on the payroll instead of seeking other places to work. 

See the full case study here or contact us today to learn more about Intelli-Hood and the benefit of kitchen hood controls.

Noise! Noise! Noise! Reduce The Noise!

The Holidays are upon us, with all the excitement and the parties. As the Grinch says, “And Then! Oh, the noise! Noise! Noise! Noise! There’s one thing I hate! All the NOISE! NOISE! NOISE! NOISE!”

Now, I am no Grinch about the holidays, but prior to my tenure here at Melink I worked for nearly 10 years as an Environmental Health and Safety Manager within a large chemical facility, and there were various work areas which exceeded noise thresholds requiring hearing protection. It was LOUD. This is where I became cognoscente of NIOSH (National Institute for Occupational Safety and Health) standards for hearing conservation,

NIOSH states continued exposure to noise above 85 dBA (adjusted decibels) over time will cause hearing loss. The volume (dBA) and the length of exposure to the sound will tell you how harmful the noise is. In general, the louder the noise, the less time required before hearing loss will occur. According to the NIOSH, the maximum exposure time at 85 dBA is eight hours.

Although we may not be able to control the noise of the holiday party or the loud toys the children will receive on Christmas day, perhaps within the working environments of commercial kitchens we can make drastic improvements and reduce the overall noise level.

Studies have been conducted over the years and dependent on many variables such as the size of the kitchen spaces, the duration of peak activity, and other various factors the overall noise level at times approach or exceed the 85dBA level, sources show a typical restaurant operates at 80 dB, although this value does not trigger hearing protection, some restaurants are known to reach 110 dB at times which is the noise level of a jackhammer! Think of the last time you were at your favorite restaurant and seated near the kitchen entrance versus the opposite side of the room.

Demand control kitchen ventilation can help not just provide energy savings but also reduce the noise levels drastically, especially over an 8-hour timeframe for employees in the kitchen spaces. When researching kitchen exhaust fans one will find that the noise levels are reported as a “sone” which depending on the static pressure of the design the noise levels can vary. A sone is a unit of loudness, how loud a sound is perceived. Doubling the perceived loudness doubles the sone value. Within fan specs of kitchen exhaust fans manufacturers indicate the “Sones” level for example a 5hp kitchen exhaust fan has a sone level ranging from 16.5 to 26 sones dependent on duct design. Per the decibel level and sones conversion chart this is equivalent to around 68.3 to 74.9 dB!

Now considering utilizing a temperature and optic based demand control kitchen ventilation, such as Intelli-Hood, can reduce fan speeds by 30-45% average fan speed over a 24hr period consider the reduction of noise exposure this provides. It is not uncommon for customers post installation of a Melink Intelli-Hood system to recognize significant noise reduction, many times commenting that during food prep hours, although the fans are “turned on” they operate at a minimum speed and it sounds like they are not even operating!

Perhaps you are in a position of influence of the decision to retrofit Demand Control Kitchen Ventilation, or perhaps evaluating and analyzing the opportunity for a client. Remember that there is more savings than simply energy that can be considered when evaluating demand control kitchen ventilation.

The Culprit of Corporate Cafeteria Energy Consumption

Corporate cafeterias have taken off over the last decade, and the trend is not slowing. Businesses and building owners have been adding new cafeterias or expanding current ones to help with recruitment of the millennial generation, boost employee retention and satisfaction, and establish a more inviting work environment. While providing a value to employees, cooperate cafeterias are one of the largest operation costs within the building. After all, food service areas account for the highest energy cost per square foot in the commercial building sector.

Cafeteria Energy Consumption Culprit:
THE KITCHEN VENTILATION SYSTEM

The expansion of cafeterias and new cooking techniques create new challenges for kitchen design, code compliance, and added ventilation among other things. A commercial building’s HVAC system accounts for about 29% of energy consumption, and up to 75% of the HVAC energy consumption is contributed to the kitchen hood ventilation system. Kitchen hoods normally run at 100% fan speed from open to close — sometimes even running for 24 hours a day. Even during slow hours of operation, the system is continuously running at 100%. Any time the fan is on, the kitchen hood’s exhaust fans are pulling perfectly good conditioned air out of the building. At the same time, the makeup air unit is trying to respond to this and is heating/cooling the air to redistribute it back into the kitchen. It is a vicious cycle of wasted energy and wasted money.

Solution:
DEMAND CONTROL KITCHEN VENTILATION (DCKV)

DCKV systems utilize optic and/or temperature sensors to actively modulate the exhaust and make up air fans based on the cooking activity within the fume hood. So what does this mean? If your kitchen has downtime and there is no active cooking, the fans will automatically lower their run speed to conserve energy. As cooking starts, fan speed will rev up appropriately until it hits the maximum speed of 100%, if necessary. This allows the highest energy savings, as well as increased comfort and safety for building occupants. DCKV is also easy to implement. It is a low-cost project that is equally effective in new construction or retro-fit during remodels. Savings from installing DCKV can be used to accelerate your payback for the addition of your corporate kitchen, making the cost of the kitchen less.

Interested in seeing how DCKV could benefit your company or commercial building? Contact us for a free energy savings report to see just how much you could save!

Effects of dynamic air flow in kitchen environments and the importance of air balancing

GROWING HOSPITALITY INDUSTRY:

As we all know, the hospitality industry is developing a lot these days. Owners are investing heavily into their hotels in order to globalize them and create unique destinations. This development is mainly due to the increase in international tourism and business travel driving the need to create different cuisine options. The multitude of cuisine options and equipment designs can have a significant impact on dynamic air flows and energy consumption.

AIR CONDITIONING IN KITCHEN:

In the hospitality industry, the focus is being given to the improvement of centralized kitchen air conditioning to ensure that the chefs working in the midst of heat are safe and comfortable. Even small-scale kitchens are focused on providing air conditioned kitchens now more than ever.

VENTILATION SYSTEMS OF OLD AND MODERN KITCHEN TRENDS:

In the earlier days, importance was generally given to extract and discharge of exhaust air alone. Whereas now, in trending commercial kitchen ventilation system, the following ventilation systems are present to do air balancing and bring comfort in the kitchen zone-wise:

  • HOT Kitchen Zone – When cooking appliances are present, exhaust air and fresh air (makeup air) systems will be present to extract thermal plumes and radiant heat.
  • COLD Kitchen Zone – The preparation area and refrigeration area have conditioned air and return air systems present.
  • Dish Washing Zone – With the heavy output of steam, systems are in place to extract the steam immediately and recycle makeup air through the area.
DYNAMIC AIR FLOW AND IMPORTANCE OF AIR BALANCING:

Dynamic Air flow occurs due to the following reasons:

  • The heat load is not calculated per the equipment specifications.
  • Selection of improper kitchen equipment that leads to variation in heat load. Examples include wrong burner design, equipment without proper insulation, wrong electrical appliance selections.
  • High air draft transfer through doors/service door/high velocity diffusers
  • Equipment placement changes. An example would be changing the positions of equipment against the original kitchen design.
  • Extraction hood is undersized as it affects suction.
  • Increase in the number of people in the building.
  • Improper selection of exhaust fan, make up air fan, and exhaust & make up air ducting system

As a result of the air draft energy savings plummet!

ILLUSTRATION:

Something that I have observed quite often, is the high draft air transfer through different doors. This is a primary cause of dynamic air flow. Optimal kitchen design would allow the natural hot air from cooking to go undisturbed.

Service door opening affecting dynamic air flow.Service door opening allowing natural air flow.

In the 1st image above, the service door is open so the hot air that is rising is disturbed due to the high draft air from the next room, creating turbulence. The high draft should be balanced to decrease energy loss.

In the 2nd image above, the service door is closed allowing the hot air to rise without disturbance.

When there is a turbulence, the temperature in the kitchen will quickly rise as the extraction does not happen correctly and it combines with exhaust and supply air. Therefore, this makes the kitchen staff become very uncomfortable, air conditioning is increased to cool down the kitchen, and the exhaust is ramped up. Because of this, extra energy is used when it could have been avoided. If this is constantly being repeated, it will result in discomfort, hygiene will be affected, and there will be a huge loss of energy.

As you are designing your next kitchen, be cognizant of the fact that kitchen design impacts more than meets the eye. Kitchen efficiency goes beyond the layout that makes it easiest for your staff to work in, it entails energy usage and safety as well.