Operating Cost for Walk-in Coolers and Freezers

Before purchasing your walk-in, you may be wondering how much it will cost to operate your walk-in.

To give you a rough estimate of how much it cost to operate a walk-in cooler or freezer, using the national average of 11.89 cents per kilowatt, look at the chart below.

*These numbers were figured using the $.0999 kilowatt hour cost. According to the Energy Information Administration this is the average cost in the United States for commercial electricity.

This chart was created using several assumptions that can affect your actual operating cost.

1. The type of insulation in the walk-in.
2. Efficiency of the refrigeration system.
3. Inside and outside temperature of walk-in.
4. Where the walk-in is located.
5. The temperature and the weight of the product entering the walk-in.
6. How often the door is opened.
7. The age of the walk-in.
8. Cost of electricity.

This is just to name a few.  If you would like to be more accurate using your electric rate, follow the instructions below. Read the rest of this entry »

EC Motor Start-up

Interesting information about EC motors that could lead to an incorrect diagnosis.

As of January 1, 2009, all walk-in manufacturing companies must sell their refrigeration units with Electronically Commutated (EC) motors. EC motors lower energy costs and significantly improve the walk-in cooler or freezer performance. These energy efficient motors are offered as a complete unit or as a drop-in replacement. Whichever your use is, if you are not familiar with the EC motor it may seem odd when you initially start it up.
When starting an EC motor, the motor must know where the rotor is located in order to start and continue to run. When power is first applied to the motor, the controller will apply a gradually increasing amount of current to all three windings in the motor over a period of 2 seconds. This will cause the rotor to move to a known location. This move will range from no movement at all if the rotor has stopped in the location needed for the next start or may be a much larger movement if it was a longer distance  from where it needed to be. With a fan blade attached, it may even overshoot and move backwards to get to the right location. After that 2 second “positioning” period the controller will start applying power to different phases in a slow rotating pattern that increases in speed over the next 2 seconds until the rotor is moving fast enough for the controller to be able to detect its location. This second phase of the start cycle usually happens so quickly that you cannot really see what is happening. Within 3 to 5 seconds of applying power, the motor should appear to be running normally, but during those first 2 seconds the movements may seem as though the unit is having troubles starting or is broken.

Own a restaurant? Tips to save time, energy, and money.

1. Make Your Menu More Efficient.

Are your menu items being prepped and cooked as efficiently as possible? Items that need to be thawed for daily food service can be defrosted in a refrigerator overnight instead of under running water reducing energy usage and conserving water. Review your menu to see if there are common ingredients or items that can all come from one source. Minimizing the number of individual deliveries you receive weekly will add to your conservation practices and reduce your delivery expenses as well as receiving time when you can be going in and out of cold storage using additional energy to bring it back to safe temperatures.

2. Switch to energy efficient light bulbs.

Subway recently switched all their light bulbs to energy efficient bulbs in all of their 2000 US franchise locations. Switching to an energy efficient light bulb can save up to $22 per bulb per year. This can add up to quite a savings over time. Also keep lights off when you don’t need them. If you don’t start serving lunch until 11 o’clock there is no reason to turn the dining room lights on until then.

Areas such as walk-in coolers or your dry store room don’t need to be illuminated all day long. Turning off lights as you leave typically unused areas is a great way to save money on your energy bill. Electrical timers can be used in these areas especially if they are commonly forgotten and left on overnight.

Higher efficiency bulbs can be used in areas that require constant lighting. Replace incandescent lights in your walk in cooler with fluorescent lights which are cooler and consume less energy. Replacing bulbs with higher efficient options will show a lower cost in your monthly bill.

3. Pre-cut and freeze many of the common vegetables you use in your restaurant or cafe.

Onions: Buy in bulk and on sale. Peel and slice or dice. Freeze one layer thick on a cookie sheet. When frozen transfer to plastic jars with screw on lids. Immediately put back in the freezer. Don’t forget to label the jars! When you need some onions in a cooked dish just shake out what you need. If they clump together shake really hard to loosen. Some of the ways we use frozen onions: sautéed or grilled on hamburgers, in omelets, in any dish that the customer asks for “extra onions” that will be cooked or at least heated. Bell peppers, Mushrooms

4. Train your staff.

Teach your staff to sort recyclables, turn off lights, and let you know if there is a leaky faucet in the wait station. Ask them to bring in their own take-home containers instead of using the restaurant take-outs.

Busy kitchen staff may often forget to do the simplest of energy efficient steps. Leaving oven doors open releases vast amounts of heat. Each time you open an oven door the temperature can drop by as much as 25o F.; watch the clock and use a timer instead. Don’t leave the convection oven or steamer door open too long or it will just continue to release heat, burning unnecessary energy to retain the proper cooking temperature.

The walk-in cooler is another door that needs to be shut at all times or cooling becomes a continuous energy pit. If doors such as the walk-in cooler are consistently left open, place spring hinges on the doors and it will automatically close, eliminating the opportunity for staff to forget to shut the door.

Read the rest of this entry »

USDA Grant Money for Rural Energy Improvements

Government money is available to help your small business become more energy efficient.

The USDA is now offering a grant and loan program to improve energy efficiency in rural areas. The REAP/RES/EEI (Rural Energy for America Program Grants/ Renewable Energy Systems/ Energy Efficiency Improvement Program) Grants Program will provide funds to architectural producers and rural small businesses to purchase and install renewable energy systems and make energy efficient improvements.

The program is designed to assist farmers, ranchers and rural small businesses that are able to demonstrate financial need. Small businesses that are located in rural areas can also apply. Most rural projects that reduce energy use and result in savings for the agricultural producer or small business are eligible as energy efficient projects. These include projects such as retrofitting lighting or insulation, or purchasing or replacing equipment with more efficient units. One of the main requirements of the grant program is that the new equipment must be more energy efficient than the current equipment. An ‘energy audit’ will be performed comparing the energy usage of the old equipment to the new anticipated energy efficient equipment.

Walk-in coolers and freezers qualify for this grant program. Older walk-ins are not as efficient as new units built today. Some of the recent changes in the industry include the requirement to provide higher insulation r-values and refrigeration units with EC motors, which are much more energy efficient than older units. These upgrades will prove your new equipment to be more energy efficient, which will save you money on energy costs. Read the rest of this entry »

Convenience Store Efficiency

The following article, Cooler Control, from the Convenience Store Decisions magazine, discusses ways to increase your walk-in cooler’s efficiency and decrease operating costs.

Convenience store chains can slash operating costs by as much as 10% with sound maintenance and general improvements to its refrigeration systems.

Operators looking for greater energy efficiency should cast an eye on their coolers, where centralized controls, lighting adjustments, basic ongoing maintenance and employee training can save them money.

“Coolers are typically an opportunity for improvements in maintenance and operational practices,” said Jerry Lawson, national manager for Energy Star Small Business and Congregations Network, a division of the U.S. Environmental Protection Agency in Washington. “With all the different types of equipment in the c-store, coolers are a key piece of the energy equation, and they are typically the most expensive to run. With the right improvements, there is an energy efficiency dollar saving opportunity.”

Where to begin? Start with the obvious.
“Keeping them clean is the biggest thing,” Lawson said. “Coolers have to breathe. Keeping those coils clean allows them to breathe; they take the air in and expel air out.”

When taking care of monthly cooler cleaning, Lawson liked to pull off the back panel and take a cloth or other type of non-steel brush to it and clean it off, then vacuum or sweep the junk up off the floor. “That’s the biggest thing to keep them running efficiently.”

Matt Lauck, director of marketing for Retail Solutions in Kennesaw, Ga., a subsidiary of Emerson Electric, said that central facility management systems can be a major tool for achieving energy efficiency in coolers. Such systems give the operator the ability to optimize energy reduction by, among other things, tracking temperatures to make sure they stay within operational norms, which obviously also has implications for food safety. “Think of it as a programmable thermostat,” he said.

Read the full article from Convenience Store Decisions

School Food Service Stimulus Package

In addition to the numerous small business grants available, the federal government has delivered a $100 million dollar food service equipment stimulus package targeted directly at public and private schools which participate in the National School Lunch Program (NSLP) and qualify (at the building level*) with a 50% or more participation in a free and reduced lunch program.

Funds have been allocated to each state education department. Funds vary by state and range from $215,000 to $12 million. The grants are competitive which means preparation is important. The window of opportunity is very narrow so this is an actionable item. The funds are intended to be dispersed within three months.

Items the schools may wish to consider include the repair, replacement or addition of walk-in coolers and freezers. Some of the reasons these qualify include: improving food safety, reducing operating costs translating into energy savings, increased storage capacity to handle expanded breakfast, lunch and snack programs. The link below contains detailed information regarding all qualifying food service equipment. A general rule of thumb is that the equipment must support the reimbursable meal program and not specifically targeted to an ala carte program.

Here is a link to the National School Nutrition Association website where school food service directors can find the most current USDA issued communication related to this process. There are links to each individual state where the food service director can view the requirements and download the required forms.

School food service directors are welcome to call on U.S. Cooler to assist with specification, sizing etc. Contact information is easily accessed via our interactive territory map.

*Participation is measured at the building level rather than the District Level. If the equipment is for a central kitchen, all buildings served by the central kitchen are listed and included in the calculation.

Get a Small Business Grant to Help Purchase Your Walk-in Cooler or Freezer

Being “green” and “energy efficient” are big advertising buzzwords today.
But besides the benefits to the environment, there are definitely good economical reasons for “going green“. There is a HUGE potential for savings on your next electric bill (you can check out our walk-in energy savings calculator). However, investing in new efficient equipment like walk-in freezers, furnaces, or stoves often present too much of an up front cost (even if they would pay for themselves in energy savings in a few years) so the purchase is delayed as long as possible. Think you can’t afford that new refrigerator or ice machine? Maybe you can with the help of your state government.

In this political environment there are many grants available for small businesses, especially when it comes to making your business more energy efficient. The following is a list of websites where you can find and apply for grants in your state (most are linked to the state’s business website but some are linked to specific energy grants). There is also an online government grant and loan search available. Different grants have different requirements and payouts (for example, some will require you to reduce energy usage by at least 20% and the state will foot 25% of the equipment bill).

Economic Development Websites:

Alabama, Alaska, Arizona, Arkansas, California, Colorado, Connecticut, Delaware, Florida, Georgia, Hawaii, Idaho, Illinois, Indiana, Iowa, Kansas, Kentucky, Louisiana, Maine, Maryland, Massachusetts, Michigan, Minnesota, Mississippi, Missouri, Montana, Nebraska, Nevada, New Hampshire, New Jersey, New Mexico, New York, North Carolina, North Dakota, Ohio, Oklahoma, Oregon, Pennsylvania, Rhode Island, South Carolina, South Dakota, Tennessee, Texas, Utah, Vermont, Virginia, Washington, West Virginia, Wisconsin, Wyoming

Walk-in Cooler & Freezer Shopping Tips

Be aware when shopping for walk-ins online that you are comparing the same size box and refrigeration. Some companies are offering smaller sized refrigeration packages, which make it look cheaper upfront but may not provide you the results you are looking for.

Some systems, whether they are coolers or freezers, are designed only to hold the temperature of the product coming in and are not designed to pull-down the temperature of the product to the desired holding temperature. Pull-down happens when there is product entering the cooler or freezer that is warmer than the desired temperature and needs to cool in a short amount of time. For example, when a restaurant owner has a large pot of soup that needs to be cooled quickly to avoid bacteria growth, the refrigeration must be able to cool the soup to the desired temperature in a reasonable and safe time while maintaining the holding temperature in the cooler/freezer. Systems designed for holding only and not to pull down the temperature of the product coming in will only work properly if products entering the box are already at the desired temperature, either cold or already frozen.

The industry standard design temperature for freezers is at -10° F. Some online companies are selling their freezer refrigeration at a holding temperature of 0° F. If you try to run a walk-in designed for 0° F holding temperature and set the thermostat to -10° F, it will run constantly trying to meet the -10° F temperature it was not designed to hold. This will shorten the life of the compressor and may cause the coil to freeze and consequently warm up the box to melting temperature, damaging the food stored inside.

Before purchasing, you must understand the difference and what implications it could have on your business. Most perishable items that are stored in a freezer are not frozen to start with and will need to freeze and stay frozen for a period of time. If the box is designed for holding temperature only and is set at 0° F, the refrigeration will work harder and longer to pull the temperature inside the box back down to 0° F once warm food is stored in the freezer. Frozen products, such as ice cream, hold up better at -10° F rather than 0° F. When a freezer goes into defrost it can raise the box temperature by 10-15°. If your box is set at 0° F, a 10-15° temperature swing can cause some products to be damaged or melted. When dealing with food it is imperative to make sure the holding temperature in the freezer is low enough to keep products frozen, protecting from bacteria or other hazards that spread through food not refrigerated correctly. (Check with your local health codes for the required holding temperature of your walk-in cooler and freezer.) It is also important to note that when refrigeration is working longer and harder, your energy costs will increase as well as the chances of your refrigeration breaking down or having inefficiencies.

Every state has requirements for storing cold food; here is an example of Illinois’s Administrative Code.

Walk-in Installation Tips

All U.S. Cooler walk-ins are test assembled in our plant prior to shipment. This ensures problem free on-site installation. If you have had problems setting up your walk-ins, we have some tips that may be helpful.

1. Receiving your walk-in: When your walk-in cooler or freezer is delivered by the freight company, it is critically important that you inventory the items delivered.

a. You must be sure when you sign the delivery receipt, you have received the freight in good condition and not damaged in anyway. The person signing the delivery receipt is responsible for inspecting the freight.
b. If you see any damage to the container or boxes, this is a good sign that you may have hidden damage. If you have a camera, take pictures of any damage to your freight, even before it is taken off the truck. Call U.S. Cooler and ask for Customer Service if you see a problem with your shipment. When you call, have your order number available. The order number allows us to pull up all details needed to answer your questions.
c. Insist that the driver does not leave until your satisfied all freight damage has been noted on the delivery receipt before the driver signs the delivery receipt.

2. Take time to read the instruction manual and review drawing: Before you get started take out the installation instructions and drawing package. Inventory your parts against the drawing to be sure you understand the layout. If you have any questions on how to assemble the walk-in call U.S. Cooler and ask for Customer Service.

3. Make sure your area where the walk-in will be installed is flat: Level is critical when installing a walk-in cooler or freezer. Before installation you should get an exact tolerance of the entire space you are planning to install the walk-in. The longer the box, the more important it is to have a level area. Floorless boxes should be shimmed inside the vinyl screed to prevent gaps and air infiltration. A liquid leveling compound is very useful for floors that are not completely level.
4. Threshold bar:  On all standard walk-ins, a threshold bar must be installed in the floor panel below the door panel before the door can be set in place. This allows for the door threshold to be anchored to the floor.

5. Line up top corners evenly: When installing panels, make sure the top of the panels are level with the adjacent panels before locking them in place. This ensures the ceiling fits properly on the routes and will keep the box square as the panels are being installed.

6. With the exception of PRO3 and Apex, all refrigeration units must have a condensation line run to the outside of the walk-in. When running any utilities, including those for refrigeration, drill into the wall panel; not the ceiling. After running all utilities, caulk around drilled holes. Follow all local building and electrical codes during installation.

View our Test-Assembly Webcam