Food Service Technology Center

Transcription

1 Food Service Technology Center Giles GGF-400 Gas Fry Kettle FSTC Report # R0 Application of ASTM Standard Test Methods F , December 2012 Prepared by: Adam Cornelius Denis Livchak Fisher-Nickel, Inc. Prepared for: Pacific Gas and Electric Company Customer Energy Efficiency Programs PO Box San Francisco, California Pacific Gas and Electric Company Food Service Technology Center. All rights reserved. 2012

2 Food Service Technology Center Background The information in this report is based on data generated at the Pacific Gas and Electric Company (PG&E) Food Service Technology Center (FSTC). Dedicated to the advancement of the foodservice industry, The FSTC has focused on the development of standard test methods for commercial foodservice equipment since The primary component of the FSTC is a 10,000 square-foot laboratory equipped with energy monitoring and data acquisition hardware, 60 linear feet of canopy exhaust hoods integrated with utility distribution systems, equipment setup and storage areas, and a state-of-the-art demonstration and training facility. The FSTC Energy Efficiency for Foodservice Program is funded by California utility customers and administered by PG&E under the auspices of the California Public Utilities Commission (CPUC). California customers are not obligated to purchase any additional services offered by the contractor. Policy on the Use of Food Service Technology Center Test Results and Other Related Information Fisher-Nickel, Inc. and the FSTC do not endorse particular products or services from any specific manufacturer or service provider. The FSTC is strongly committed to testing foodservice equipment using the best available scientific techniques and instrumentation. The FSTC is neutral as to fuel and energy source. It does not, in any way, encourage or promote the use of any fuel or energy source nor does it endorse any of the equipment tested at the FSTC. FSTC test results are made available to the general public through technical research reports and publications and are protected under U.S. and international copyright laws. Disclaimer Copyright 2012 Pacific Gas and Electric Company Food Service Technology Center. All rights reserved. Reproduction or distribution of the whole or any part of the contents of this document without written permission of FSTC is prohibited. Neither, Fisher-Nickel, Inc., PG&E nor any of their employees, or the FSTC, make any warranty, expressed or implied, or assume any legal liability of responsibility for the accuracy, completeness, or usefulness of any data, information, method, product or process disclosed in this document, or represents that its use will not infringe any privatelyowned rights, including but not limited to, patents, trademarks, or copyrights. Reference to specific products or manufacturers is not an endorsement of that product or manufacturer by Fisher-Nickel, Inc., the FSTC, or PG&E. In no event will Fisher-Nickel, Inc. or PG&E be liable for any special, incidental, consequential, indirect, or similar damages, including but not limited to lost profits, lost market share, lost savings, lost data, increased cost of production, or any other damages arising out of the use of the data or the interpretation of the data presented in this report. Retention of this consulting firm by PG&E to develop this report does not constitute endorsement by PG&E for any work performed other than that specified in the scope of this project. Legal Notice This report was prepared as a result of work sponsored by the California Public Utilities Commission (CPUC). It does not necessarily represent the views of the CPUC, its employees, or the State of California. The CPUC, the State of California, its employees, contractors, and subcontractors make no warranty, express or implied, and assume no legal liability for the information in this report; nor does any party represent that the use of this information will not infringe upon privately owned rights. This report has not been approved or disapproved by the CPUC nor has the CPUC passed upon the accuracy or adequacy of the information in this report. Revision History Revision num. Date Description Author(s) 0 December 2012 Initial release A. Cornelius, D. Livchak Food Service Technology Center Page 2 of 29

3 Contents Page Executive Summary... 5 Introduction... 7 Background... 7 Objectives... 7 Equipment Description... 8 Methods and Results... 9 Setup and Instrumentation... 9 Measured Energy Input Rate Test Boneless Chicken Tests French Fry Tests Energy Cost Model Appendix A: Glossary of Terms Appendix B: Additions, Deviations, and Exclusions Appendix C: Equipment Specifications Appendix D: Equipment Test Summary Report Additional References Food Service Technology Center Page 3 of 29

4 Figures Page Figure 1: Giles GGF-400 Fry Kettle... 5 Figure 2: Giles GGF-400 Fry Kettle Vat with Wire Mesh Basket... 8 Figure 3: Preheat Characteristics to 320 F Figure 4: Idle Characteristics at 325 F Figure 5: Boneless Chicken Cooking Profile Figure 6: Preheat Characteristics to 340 F Figure 7: Idle Characteristics at 350 F Figure 8: French Fry Barrel Load Cooking Profile Tables Page Table 1: Summary of Giles GGF-400 Fry Kettle Performance... 6 Table 2: Equipment Specifications... 8 Table 3: Test Instrumentation Inventory... 9 Table 4: Input Rate Test Results Table 5: Preheat Test Results to 320 F Table 6: Idle Test Results at 325 F Table 7: Boneless Chicken Cooking-Energy Efficiency and Production Capacity Test Results Table 8: Preheat Test Results to 340 F Table 9: Idle Test Results at 350 F Table 10: French Fry Barrel Load Cooking-Energy Efficiency and Production Capacity Test Results Table 11: Daily Operation Assumptions Table 12: Estimated Energy Consumption and Cost Food Service Technology Center Page 4 of 29

5 Executive Summary Kettle fryers are used for deep-frying a variety of foods, from chicken to doughnuts to vegetables such as potatoes and popcorn. The Giles GGF-400 Fry Kettle (Figure 1) is a 16-inch gas kettle fryer with a nominal frying oil capacity of 45 pounds. The fryer has dual burners, a gas heat exchanger, and a 45,000 Btu/h rated input rate. Its automatic oil filtration system rinses, drains, and filters oil in a single step greatly reducing the labor and risk involved in manually filtering hot fryer oil. The Auto-Basket Lift can automatically lift the basket out of the kettle when the frying time is complete to avoid overcooking. A solid state control panel controls the fryer s temperature, cool and solid shortening melt cycles, mechanical basket lift, warning messages, and boil out program. FSTC engineers tested the fryer under the tightly controlled conditions of the American Society for Testing and Materials (ASTM). Kettle fryer performance results were characterized by preheat time and energy consumption, idle energy consumption rate, cooking-energy efficiency, production capacity, and the average recovery time of the frying medium temperature between cooking runs. Preheat energy consumption and idle energy rate were documented in all tests. The test method was based on the Standard Test Method for the Performance of Pressure Fryers (F ), and cooking data was gathered from frying boneless chicken breasts. Because kettle fryers are used to cook a variety of foods, each of which can impact the fryer s performance differently, FSTC engineers compared the Giles GGF-400 s performance results when cooking boneless chicken breasts against performance results when cooking French fries. French fry heavy-load results were determined by applying the ASTM test method F : Standard Test Method for the Performance of Open Deep Fat Fryers. When cooking boneless chicken breasts, the fryer achieved a cooking-energy efficiency of 53.4% while producing 48.9 lb of chicken per hour. The average oil recovery time was 0.65 minutes. When cooking French fries, the Giles fryer achieved a cooking-energy efficiency of 53.6% while producing 38.6 lb of fries per hour. The average oil recovery time was 1.36 minutes. Figure 1: Giles GGF-400 Fry Kettle A summary of the test results is presented in Table 1. Food Service Technology Center Page 5 of 29

6 Table 1: Summary of Giles GGF-400 Fry Kettle Performance Boneless Chicken Breasts French Fries Rated Energy Input Rate (kw) 45,000 45,000 Measured Energy Input Rate (Btu/h) 44,475 44,475 Preheat: Preheat Target Oil Temperature ( F) Final Preheat Temperature ( F) Preheat Time (min) Energy Consumption (Btu) 7,273 7,998 Idle Energy Rate (Btu/h) 3,535 3,835 Cook Time (min) Cooking-Energy Efficiency (%) a 53.4 ± ± 4.5 Production Capacity (lb/h) a,b 48.9 ± ± 1.3 Average Recovery Time (sec) a The ± range in this row indicates the experimental uncertainty in the test result based on three test runs. b Boneless chicken production capacity was based on a heavy-load cooking test. Test times included intervals between barrel loads for recovery, loading and unloading. Food Service Technology Center Page 6 of 29

7 Introduction Background Kettle fryers are used for deep-frying a variety of foods, from chicken to doughnuts to vegetables such as potatoes and popcorn. The Giles GGF-400 Fry Kettle is a 16-inch gas kettle fryer with a nominal frying oil capacity of 45 pounds. The fryer has dual burners, a gas heat exchanger, and a 45,000 Btu/h rated input rate. Its automatic oil filtration system rinses, drains, and filters oil in a single step greatly reducing the labor and risk involved in manually filtering hot fryer oil. The Auto-Basket Lift can automatically lift the basket out of the kettle when the frying time is complete to avoid overcooking. A solid state control panel controls fryer temperature, cool and solid shortening melt cycles, mechanical basket lift, warning messages, and boil out program. The test method in this report was approved and ratified by the ASTM in standard F This method allows for equipment benchmarking in a way that users can make meaningful comparisons between appliances. ASTM equipment performance standards can be used to estimate an appliance s contribution to the energy consumption of an end-user s kitchen. The ASTM F test method characterizes the performance of kettle fryers using boneless chicken breasts as the food product and 325 F as the target operating temperature. In order to provide comparable results to other deep fat fryers, additional testing was conducted on the Giles GGF-400 Fry Kettle using ASTM standard F This test method characterizes the performance of deep fat fryers when cooking French fries using 350 F as the target operating temperature. The glossary in Appendix A is provided so that the reader has a quick reference to the terms used in this report. Objectives The objective of this report is to examine the operation and performance of the Giles GGF-400 Fry Kettle under conditions specified in the ASTM test methods mentioned above. The scope of this testing is as follows: 1. Verify that the fryer is operating at the manufacturer s rated energy input. 2. Determine the time and energy required to preheat the fryer from room temperature to operating conditions. 3. Calculate the fryer s preheat energy rate and idle energy rate. 4. Determine the fryer s cooking energy consumption, product cook time, and recovery time using boneless chicken breasts as the test product under heavy-load conditions. 5. Determine the fryer s cooking energy rate, cooking-energy efficiency, and production capacity using frozen, ¼-inch French fries as the test product. 6. Estimate the annual operating cost for the fryer using a standard cost model. Food Service Technology Center Page 7 of 29

8 Equipment Description The Giles GGF-400 Fry Kettle (see Figure 1) is a gas kettle fryer with a total rated input of 45,000 Btu/h. The fryer has dual burners and a gas heat exchanger, which heats the oil along the perimeter of the pot. Food is placed in the fry basket and mechanically lowered into the kettle. The Giles GGF-400 Fry Kettle is equipped with digital thermostatic controls which can be programmed to cook a single product at multiple temperatures. In addition to manually raising and lowering the fry basket, an operator can program the fryer s Auto-Basket Lift to raise the basket at the end of the cooking cycle. An automatic oil Figure 2: Giles GGF-400 Fry Kettle Vat with Wire Mesh Basket filtration system drains and filters the used oil, and refills the kettle with replacement oil. The touch pad control system is located along the top edge of the fryer s face, and includes the manual and automatic basket lift operation, cool cycle, solid shortening melt cycle, low oil and low drain warning messages, and boil out program. The latest model of the GGF-400 Fry Kettle has a wire mesh basket, designed to improve cooking performance (See Figure 2). Equipment specifications are listed in Table 2 and the manufacturer s literature is provided in Appendix C. Table 2: Equipment Specifications Manufacturer Giles Model GGF-400 Serial Number S Generic Equipment Type 16-inch gas kettle fryer Rated Input 45,000 Btu/h Oil Capacity 45 lb Construction Stainless steel Controls Computer controller. Digitally-controlled temperature. Eight programmable menu keys. Temperature Range 75 F F Fry Vat Dimensions 12.75" depth x 15.88" diameter Fry Basket Dimensions 10.25" depth x 12.38" diameter External Dimensions (W x D x H) 24.38" x 42.13" x 44.13" Food Service Technology Center Page 8 of 29

9 Methods and Results Setup and Instrumentation FSTC researchers installed the fryer on a tiled floor under a four-foot-deep canopy hood, which operated at a nominal exhaust rate of 300 cfm per linear foot. The hood was mounted six feet, six inches above the floor, with at least six inches of clearance between the vertical plane of the fryer and the hood s edge. All test apparatus were installed in accordance with Section 9 of the ASTM test method. Table 3 lists the equipment used to measure the fryer s temperature and energy. To measure temperatures in the cold zones, the cook zones, flue, and at the fryer s thermostat, researchers used Type-K thermocouples with a welded junction. Two thermocouples were placed in the cook zone: one behind the heating element near the thermostat (slightly below the top edge of the element); the other behind the heating element on the opposite side of the vat. The thermocouples in the cook zone did not touch either the element or the kettle wall. The cold zone thermocouple was supported from below, not in contact with the kettle s surface, so that the temperature of the cold zone reflected the temperature of the frying medium, rather than the kettle s surface temperature. The cold zone temperature was measured towards the center of the kettle, one inch from the bottom. Table 3: Test Instrumentation Inventory Description (I.D.) Manufacturer Model Measurement Range Gas meter (ALB205) Sensus R CFH 275 CFH Gas meter (ALB206)* Sensus R CFH 275 CFH Electric meter (ALB204) Scale (ALA104) Scale (ALB208) Radian Research Sartorius Group Sartorius Group Metronic RM-10 Acculab SCI20B Acculab SCI20B Resolution Calibration Date Due Date 0.05 ft 3 12/08/ /08/ ft 3 12/08/ /08/ A 50.0 A Wh 12/10/ /10/ lb 44 lb lb 12/06/ /06/ lb 44 lb lb 12/29/ /29/2012 Thermometer (ALE502) Fluke 52 II -200 C 1,372 C 0.1 C 12/29/ /29/2012 *Gas Meter ALB-206 was used for all boneless chicken breast cooking tests and for calculating results for one set of input, preheat, and idle test replicates.. Gas energy was measured with a calibrated gas meter that generated a pulse for each 0.05 cubic foot of gas used. Electrical power and energy were measured with a calibrated watt/watt-hour transducer that generated a pulse for every watt-hours generated. The gas meter, watt-hour transducer, and thermocouples were connected to a data logger which recorded data every five seconds. Food Service Technology Center Page 9 of 29

10 The fryer was filled with 100% canola oil as the frying medium. Oil was used for all tests. Measured Energy Input Rate Test Rated energy input rate is the maximum or peak rate at which the fryer consumes energy, as specified on the fryer s nameplate. Measured energy input rate is the maximum or peak rate of energy consumption which is recorded during a period when the heating elements are fully energized (such as preheat). The measured energy input rate of the Giles GGF-400 Fry Kettle was taken from a single four-minute test, with the first minute discarded during the heating elements warm-up period. This procedure ensured that the fryer was operating at a measured energy input rate that was within ±5% of its rated energy input rate. The energy input rate was recorded from the second to the fourth minute of preheat and determined to be 44,475 Btu/h (a difference of 1.2% from the nameplate rating). Table 4 summarizes the results from the input test. Table 4: Input Rate Test Results Rated Energy Input Rate (Btu/h) 45,000 Measured Energy Input Rate (Btu/h) 44,475 Percentage Difference (%) 1.2 Boneless Chicken Tests Researchers at the Food Service Technology Center conducted tests on the Giles GGF-400 Fry Kettle according to ASTM standard F , using a target oil temperature of 325 F to determine preheat time and energy consumption, as well as the idle energy rate. This target oil temperature was used to cook boneless chicken breasts when determining cooking-energy efficiency, production capacity, and average recovery time of the frying medium temperature. Thermostat Calibration Thermostat calibration was verified by allowing the fryer to operate with the thermostat set to the specified operating temperature of 325 F for a stabilization period of 30 minutes. The cook zone oil temperature was then monitored and recorded every five seconds for a period of at least three complete thermostat cycles. If the average cook zone oil temperature during this time was more than 330 F or less than 320 F, the controls were adjusted, the fryer was allowed to re-stabilize for at least 30 minutes, and the cook zone oil temperature was again monitored for at least three complete thermostat cycles. This process was repeated until an average Food Service Technology Center Page 10 of 29

11 fryer temperature of 325 ± 5 F was reached. With the thermostat set to an indicated 307 F on the Giles GGF- 400 Fry Kettle, the cook zone oil temperature averaged 326 F. Preheat Test The preheat tests were conducted after the kettle s cook zone had been stabilized to room temperature overnight. Recording began when the fryer was first turned on, so any time delay before the powering of the heating elements after the fryer was turned on was included in the test. The fryer was preheated from room temperature (75 ± 5 F) to 320 F, and the time and energy recorded. Although the preheat oil temperature for ASTM standard is 325 F, research at the Food Service Technology Center has indicated that the kettle s cook zone is sufficiently preheated and ready to cook when the oil temperature is within 5 F of its target. The GGF- 400 Fry Kettle prompts the user to stir the oil after preheat to prevent oil temperature stratification. Over the course of the preheat tests, the fryer reached a ready-to-cook state averaging 9.89 minutes, while consuming 7,273 Btu of natural gas and 10 Wh of electric control energy. Figure 3 illustrates the temperature profile when preheated to 320 F for one of the tests Preheat to 320 F Cook Zone Oil Temperature ( F) Test Time (min) Figure 3: Preheat Characteristics to 320 F Food Service Technology Center Page 11 of 29

12 Idle Test After the fryer was preheated to 320 F, it was allowed to stabilize for at least one hour before beginning the idle tests. Time and energy consumption were monitored over a three-hour period to determine the idle energy rate. During this period, the fryer s natural gas idle energy rate was 3,535 Btu/h and the control energy was found to be 20 W. Figure 4 shows the idle characteristics for the fryer at the 325 F target oil temperature Cook Zone Oil Temperature ( F) Test Time (h) Figure 4: Idle Characteristics at 325 F Tables 5 and 6 summarize the results from preheat to 320 F and idle tests at 325 F, respectively. Table 5: Preheat Test Results to 320 F Ambient Temperature ( F) 72.4 Final Preheat Cook Zone Oil Temperature ( F) 321 Duration (min) 9.89 Gas Energy Consumption (Btu) 7,263 Control Electric Energy Consumption (Wh) 10 Food Service Technology Center Page 12 of 29

13 Table 6: Idle Test Results at 325 F Ambient Temperature ( F) 72.5 Average Oil Temperature ( F) 328 Gas Energy Rate (Btu/h) 3,535 Control Energy Rate (W) 20 Cooking Tests To determine the cooking-energy efficiency, production capacity, and recovery rate when frying boneless chicken breasts, five-ounce whole meat, boneless, skinless chicken breasts were breaded with all-purpose enriched white flour using water chilled to F. In each replicate, the average initial temperature of the chicken breasts sampled prior to submerging them in the fry basket was 44 F. Before beginning each replicate, the fry basket filled to the indicated fill line with oil and the fryer s temperature stabilized at 325 F for at least one hour. During the stabilization period, the cold zone was stirred 10 to 15 minutes prior to the cooking test. Each load of chicken was weighed, and then cooked for an average of minutes, stirring vigorously during cooking to minimize product clumping. The cooking test involved barrel load cooking consisting of five consecutively-cooked loads of 32 chicken breasts each. Three replicates of these barrel loads were conducted during the course of the cooking tests. In each cooking test replicate, recovery and loading time were included for each of the cook times. The first load in each replicate was used for temperature stabilization only, and the results discarded. The remaining four loads were included in the calculation. The fry basket was scraped of breading debris after each barrel load. After each replicate, the chicken was weighed again, and the final temperatures of 10 randomly-selected chicken breasts were recorded. The weight loss across the three barrel loads ranged from 28.81% to 29.68%; average final temperatures ranged between 188 F and 190 F. Cooking-energy efficiency is a measure of how much of the energy that a piece of equipment consumes is actually delivered to the food product during the cooking process. Cooking-energy efficiency is therefore defined by the following relationship: Cooking Energy Efficiency = Energy to Food Energy to Fryer The average heavy-load cooking-energy efficiency across these three replicates was 53.4%, with an average production capacity of 48.9 lb of boneless chicken breasts per hour; the fryer took an average of 0.65 minutes to recover after each run. Food Service Technology Center Page 13 of 29

14 A profile for the barrel load test using boneless chicken breasts is illustrated in Figure 5. Stabilization Test Run Recovery Cook Zone Oil Temperature ( F) Chicken breasts placed in oil Chicken breasts removed from oil Run 1 (stabilization only) Run 2 Run 3 Run 4 Run Test Time (min) Figure 5: Boneless Chicken Cooking Profile Table 7 summarizes the performance of the Giles GGF-400 Fry Kettle when cooking boneless chicken breasts averaged across all three test replicates. Table 7: Boneless Chicken Cooking-Energy Efficiency and Production Capacity Test Results Cook Time (min) Gas Cooking Energy Rate (Btu/h) 36,226 Control Energy Rate (W) 60 Energy to Food (Btu/lb) 398 Energy to Fryer (Btu/lb) 745 Cooking-Energy Efficiency (%) 53.4 ± 4.7 Production Capacity (lb/h) 48.9 ± 1.6 Average Recovery Time (min) 0.65 Food Service Technology Center Page 14 of 29

15 French Fry Tests To understand how the Giles GGF-400 Fry Kettle performed under different conditions using different food products, and to provide comparative data against other deep fat fryers, researchers also tested the fryer according to ASTM standard F , using a target oil temperature of 350 F to determine preheat time and energy consumption, as well as the idle energy rate. This target oil temperature was used to cook French fries when determining cooking-energy efficiency, production capacity, and average recovery time of the frying medium temperature. Thermostat Calibration Thermostat calibration was verified by allowing the fryer to operate with the thermostat set to the specified operating temperature of 350 F for a stabilization period of 30 minutes. The cook zone oil temperature was then monitored and recorded every five seconds for a period of at least 15 minutes. If the average cook zone oil temperature during this time was more than 355 F or less than 345 F, the controls were adjusted, the fryer was allowed to re-stabilize for 30 minutes, and the cook zone oil temperature was again monitored for at least 15 minutes. This process was repeated until an average fryer temperature of 350 ± 5 F was reached. With the thermostat set to an indicated 335 F on the Giles GGF-400 Fry Kettle, the cook zone oil temperature averaged F. Preheat Test The preheat tests were conducted after the kettle s cook zone had been stabilized to room temperature overnight. Recording began when the fryer was first turned on, so any time delay before the powering of the heating elements after the fryer was turned on was included in the test. The fryer was preheated from room temperature (75 ± 5 F) to 340 F, and the time and energy recorded. During preheat the fryer overshot the target oil temperature in order to stabilize at the idle temperature, as seen in Figure 6. The GGF-400 Fryer prompts the user to stir the oil after the preheat to prevent oil temperature stratification. Over the course of the preheat test, the fryer reached a ready-to-cook state in minutes while consuming 7,998 Btu of natural gas and 10 Wh of electric control energy. Food Service Technology Center Page 15 of 29

16 Preheat to 340 F Cook Zone Oil Temperature ( F) Test Time (min) Figure 6: Preheat Characteristics to 340 F Idle Test After the fryer was preheated to 340 F, it was allowed to stabilize for at least one hour before beginning the idle tests. Time and energy consumption were monitored over a three-hour period to determine the idle energy rate. During this period, the fryer s natural gas idle energy rate was 3,835 Btu/h and the control energy was found to be 20 W. Figure 7 shows the idle characteristics for the fryer at the 350 F target oil temperature. Food Service Technology Center Page 16 of 29

17 Cook Zone Oil Temperature ( F) Test Time (h) Figure 7: Idle Characteristics at 350 F Tables 8 and 9 summarize the results from preheat tests to 340 F and idle tests at 350 F, respectively. Table 8: Preheat Test Results to 340 F Final Preheat Cook Zone Oil Temperature ( F) 341 Duration (min) Gas Energy Consumption (Btu) 7,998 Control Electric Energy Consumption (Wh) 10 Table 9: Idle Test Results at 350 F Average Oil Temperature ( F) 354 Gas Energy Rate (Btu/h) 3,835 Control Energy Rate (W) 20 Food Service Technology Center Page 17 of 29

18 Cooking Tests To determine the cooking-energy efficiency, production capacity, and recovery rate when cooking French fries, heavy-load cooking tests were performed using ¼" par-cooked, frozen shoestring potatoes. Researchers tested the fryer using five-pound French fry loads, which were weighed prior to beginning the tests. Six stirup loads were conducted to determine the frying time needed to reach the required weight loss of 30 ± 1%. The French fry cook time was determined to be 3.25 minutes. The cooking tests consisted of three replicates of barrel load cooking runs, with a stabilization interval of nine to ten minutes between each test replicate. Before beginning each replicate, the kettle was filled to the indicated fill line with oil and stabilized at 350 F for one hour. During the barrel load cooking, multiple loads of frozen French fries were cooked consecutively, with enough time between loads for the fryer to recover to cooking temperature before starting the next run in the test replicate. These recovery periods were included in the cook times. After cooking the French fries and allowing them to drip for two minutes, the fries were weighed again and recorded. Across the three test replicates, a total of 15 cooked loads of fries were included in the calculations. In each of the three test replicates conducted after the stir-up load, a total of six loads were run; the first load was discarded to stabilize the fryer and the remaining five were included in the calculations. A profile for the cooking test using French fries for one of the runs is illustrated in Figure 8. The weight loss across the three test replicates ranged from 29.8% to 31.6%. Average heavy-load cookingenergy efficiency across the three replicates was 53.6%, with an average production capacity of 38.6 lb of French fries per hour and an average oil recovery time of 1.36 minutes. Food Service Technology Center Page 18 of 29

19 Stabilization Test Load Recovery Cook Zone Oil Temperature ( F) Fries placed in oil Fries removed from oil Run 1 (stabilization only) Run 2 Run 3 Run 4 Run 5 Run Test Time (min) Figure 8: French Fry Barrel Load Cooking Profile Table 10 summarizes the performance of the Giles GGF-400 Fry Kettle when cooking French fries. Table 10: French Fry Barrel Load Cooking-Energy Efficiency and Production Capacity Test Results Cook Time (min) 3.29 Gas Cooking Energy Rate (Btu/h) 40,724 Control Energy Rate (W) 70 Energy to Food (Btu/lb) 569 Energy to Fryer (Btu/lb) 1061 Cooking-Energy Efficiency (%) 53.6 ± 4.5 Production Capacity (lb/h) 38.6 ± 1.3 Average Recovery Time (min) 1.36 Energy Cost Model The ASTM performance test methods and results can be used to estimate annual energy consumption for the Giles GGF-400 Fry Kettle in a real-world operation. Based on the ASTM test results using boneless chicken Food Service Technology Center Page 19 of 29

20 breasts, FSTC engineers developed a simple model to calculate the relationship between the various cost factors (e.g., preheat, idle, and cooking costs), then used that model to estimate the fryer s annual operating costs. Table 11 shows the assumptions for the fryer s daily operation. Table 11: Daily Operation Assumptions Operating Time per Day (h) 12 Operating Days per Year (day) 365 Number of Preheats per Day 1 Total Amount of Food Cooked per Day (lb) 150 Based on the assumptions above, total daily energy consumption was determined by adding the daily cooking, idle, and preheat energy consumed when cooking boneless chicken breasts: Where: E daily = Eh + Ei + np E p Edaily = Daily energy consumption Eh = Daily energy imparted to food Ei = Daily energy consumed during idle np = Number of preheats per day Ep = Daily energy consumed during preheat A more detailed explanation of this formula is illustrated below: Where: W PC W n t + PC 60 p p E daily = qgas, h + qgas, i ton np E p Edaily = Daily energy consumption W = Pounds of food cooked per day PC = Production capacity qgas,h = Heavy-load cooking gas energy rate qgas,i = Idle gas energy rate ton = Total time the equipment is on per day np = Number of preheats per day tp = Duration of preheat (in minutes) Food Service Technology Center Page 20 of 29

21 Ep = Daily energy consumed during preheat Assuming the Giles GGF-400 Fry Kettle cooked 150 lb of boneless chicken breasts over a 12-hour day, operated 365 days a year, and had one preheat per day, it is estimated that the fryer would consume 545 therms of gas annually. Using a rate of $1.00 per therm, the estimated operational cost of the Giles GGF-400 Fry Kettle is $547 per year. Table 12 summarizes the annual energy consumption and associated energy cost for the fryer under this scenario. Table 12: Estimated Energy Consumption and Cost Gas Preheat Energy (Btu/day) 7,273 Gas Cooking Energy (Btu/day) 111,123 Gas Idle Energy (Btu/day) 30,994 Total Gas Energy (Btu/day) 149,389 Annual Gas Consumption (therms/year) a 545 Annual Cost ($/year) b 545 a One therm=100,000 Btu. b Fryer gas energy costs are based on $1.00/therm. Food Service Technology Center Page 21 of 29

22 Appendix A: Glossary of Terms Barrel Load Cooking Cooking multiple loads of a food product consecutively, allowing the fryer to recover to cook temperature between loads. Cold Zone The volume of oil in a fryer, below heating elements or heat exchanger surfaces, which remains cooler than the cook zone. Cook Zone The volume of oil in a fryer where food is cooked. Cooking Energy (Btu, kwh) The total energy consumed by a piece of equipment as it is used to cook a food product under specified test conditions. Cooking-Energy Efficiency (%) The percentage of total cooking energy which has been input to a food product during a cooking test; Expressed as the ratio of the quantity of energy imparted into food to amount of energy input to the appliance. Cooking Energy Rate (kw, Btu/h, or kbtu/h) Average rate of energy consumption, in hours, during a cooking test. Energy to Food (Btu/lb) Energy consumed by the food during the cooking test per initial weight, in pounds, of food cooked. Energy to Fryer (Btu/lb) Energy consumed by the fryer during the cooking test per initial weight, in pounds, of food cooked. Energy includes sum of all fuel types used (i.e. energy for heating fryer, plus electric energy used by fryer controls). Food Product A type of product (e.g. chicken, potatoes) designated by a cooking standard and prepared according to a test method which is used to determine an appliance s cooking performance. Frying Medium Heat transfer fluid used by the kettle fryer to cook the food product. Usually shortening or other oil (e.g, corn, canola) used for deep frying. Idle Energy Rate (kw or Btu/h) The rate of energy consumption by a piece of equipment per hour while it is holding or maintaining a stabilized operating condition or temperature. Idle Temperature ( F) The temperature of the cook zone (either selected by the operator or specified for a controlled test) that is maintained by the fryer under an idle condition. Kettle Fryer A piece of equipment which is filled with a deep cooking container of oil/fat to a depth where the food product is supported by displacement of the frying medium, rather than by the bottom of the vessel. Measured Energy Input Rate (kw, Btu/h, or kbtu/h) The peak rate at which a piece of equipment will consume energy, typically measured during preheat (i.e. the period of operation when all burners or elements are on ). Does not include energy used for equipment controls. Preheat Energy (kwh, Wh, or Btu) The total amount of energy consumed by a piece of equipment during the preheat period (from ambient temperature to a specified and calibrated preheat temperature or set point). Preheat Energy Rate ( F/min) The rate, in degrees Fahrenheit per minute, at which the equipment increases temperature during preheat. Preheat Time (min) The time required for an piece of equipment to heat from the ambient room temperature (75 ± 5 F) to a specified (and calibrated) preheat temperature or thermostat set point. Production Capacity (lb/h) Maximum rate, in pounds per hour, at which a piece of equipment can bring a specified product to a specified cooked condition. Uncertainty Measure of systematic & precision errors in specified instrumentation or measure of repeatability of a reported test result. Rated Energy Input Rate (kw, W or Btu/h) Maximum or peak rate at which a piece of equipment consumes energy, as rated by manufacturer and specified on the nameplate. Resolution The smallest change in a measured input signal that can be reliably detected by an instrument. Also known as sensitivity. Temperature Set Point ( F) Targeted temperature set by equipment controls. Test Method A definitive procedure for the identification, measurement and evaluation of one or more qualities, characteristics, or properties of a material, product system, or service that produces a test result. Typical Day A sample day of average equipment usage based on observations and/or operator interviews. Used to develop an energy cost model for a given piece of equipment. Food Service Technology Center Page 22 of 29

23 Appendix B: Additions, Deviations, and Exclusions Energy Input Rate Tests For all energy input rate tests, oil was used in lieu of water, as specified in section of ASTM standards F and F Cooking Tests Only a heavy-load test was performed for French fry cooking tests, rather than light-load and heavyload tests specified in section 4.4 of ASTM standard F Food Service Technology Center Page 23 of 29

24 Appendix C: Equipment Specifications Food Service Technology Center Page 24 of 29

25 Appendix C: Equipment Specifications (Continued) Food Service Technology Center Page 25 of 29

26 Appendix D: Equipment Test Summary Report Food Service Technology Center Page 26 of 29

27 Appendix D: Equipment Test Summary Report (Continued) Food Service Technology Center Page 27 of 29

28 Appendix D: Equipment Test Summary Report (Continued) Food Service Technology Center Page 28 of 29

29 Equipment Test Report Page 29 of 29 Additional References [ASTM] American Society for Testing and Materials. 2010a. Designation F : Standard Test Method for Performance of Open Deep Fat Fryers. In: Annual book of ASTM standards. Volume 15.12, Livestock, Meat, and Poultry Evaluation Systems; Food Service Equipment. West Conshohocken, PA: ASTM International. [ASTM] American Society for Testing and Materials. 2010b. Designation F : Standard Test Method for Performance of Pressure Fryers. In: Annual book of ASTM standards. Volume 15.12, Livestock, Meat, and Poultry Evaluation Systems; Food Service Equipment. West Conshohocken, PA: ASTM International. Giles Enterprises, Inc Dec. Giles GGF-400 Fry Kettle specification sheet. < GilesProucts/SpecSheets/ 65467%20Giles%20GGF%20400%20SPEC%20SHEET.pdf>. Accessed 2012 Feb. Food Service Technology Center

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