Case Studies
Applebee's - Staying a Step Ahead
Analyzing the Grease Lock System, a 2nd Generation Disposable Exhaust Hood Filtration System By Joe Salpietra
Constantly managing and improving facility operations is critical to any company’s ability to compete effectively. Success in today’s markets depends on the ability to balance a stream of new products and processes to stay competitive. Successful restaurant operators are constantly evaluating every area of operations to ensure that productivity and cost objectives are realistic and attainable.
Recently, one of the largest franchisees in the Applebee’s Restaurant organization, Apple American Group (“AAG”) investigated a new product to evaluate how it might benefit their restaurant operations.
The Situation - Grease in the Kitchen Exhaust System
Managing grease in kitchen exhaust systems can be challenging for any restaurant operator. Until recently, the only products available attempted to deal with grease in the exhaust system after the grease had entered the ducts. Listed metal baffle grease filters are not very effective at stopping the grease particulates that enter into the exhaust ducts. Recently, some metal baffle filters have become available that have a slightly improved grease capture efficiency. Metal baffle grease filters and other products that attempt to assist with reducing grease accumulation in the exhaust system, such as UV systems, waterwash hood systems, rooftop ESP’s, etc… all try to deal with the grease after it has already entered the ducts and/or extractor motor. However, these alternatives are very costly to purchase and they still require the same or even more intense nightly cleaning practices. The result is a significant increase in the cost drivers, such as labor, water consumption, chemical usage, etc... which has made these alternatives not very widely used in the marketplace.
However, now a new listed product has been introduced, 2nd generation Disposable Grease Exhaust Filters. Recently, AAG has tested one of these new systems to determine the potential impact on its operating and fire safety practices.
A Little Background
Most local and state regulatory codes require that exhaust hoods, ducts and extractor motors be routinely inspected. If upon inspection they are found to be dirty then they must be cleaned. The result is usually a costly hood cleaning being performed at least quarterly because there has been no widespread implementation of any system that successfully prevented grease from entering into the exhaust system. In high volume restaurants or those cooking over solid fuel, exhaust system cleaning may be required monthly or even multiple times per month. This process of cleaning the exhaust system typically occurs late at night requiring the restaurant to either let a 3rd party cleaning service enter the building without an employee on-site or pay for an employee to remain throughout the cleaning process. Either option is not particularly attractive to the manager. Additionally, the cleaning process is often disruptive to facility operations due to cooking equipment being moved around, pilot lights going out, equipment getting wet from the cleaning process, grease being tracked across the roof, etc... Also, because the work is usually done late at night, on the roof or inside the ducts, it is difficult to confirm how effective the cleaning process was at actually removing the buildup of greasy effluent from inside the extraction system. For these reasons, many operators implement many additional exhaust system cleaning activities in an attempt to keep the exhaust systems cleaner for longer periods of time so that the 3rd party cleanings are not required more frequently. The AAG, like many multi-unit operators, have specific activities for maintaining the kitchen exhaust system. (See Table 1) These activities, result in a significant expense for the restaurant when all costs are truly evaluated.
The Southern California and Nevada Region of AAG, led by Market President Mike Hebert recognized that the total costs of the exhaust system cleaning and maintenance procedures, as required by AAG operating policy, was dramatically more than just the cost of a quarterly 3rd party hood cleaning invoice. In fact, when all costs were factored into the analysis, total costs of maintaining the exhaust hood easily exceeded $6,500 annually, per restaurant (See Table 2). What further concerned Mike and his Southern California and Nevada Management Team was that even with the comprehensive nightly hood-cleaning regimen as required by AAG, the fact remained that none of the processes worked to proactively prevent or reduce the amount of grease effluent entering the extraction system. Therefore, with significant grease effluent still entering the exhaust hood and ducts daily, fire risk associated with greasy buildup was still an ongoing concern and total hood maintenance costs were high.
In an attempt to significantly reduce the amount of grease effluent that enters the extraction system, Mike Hebert authorized an investigation into the benefits of the Grease Lock System ("GLS") made by Ellis Fibre USA (see Table 3). The GLS is a 2nd generation disposable exhaust hood filtration system that incorporates a proprietary blend of natural fibers with a disposable internal stabilizer frame. The technological improvements allows the 2nd generation models to have higher grease holding capacity and perform in high heat or flame environments without the need of expensive stainless steel support frames or heat shields. A few of the promoted claims of the Grease Lock System are that the proprietary design provides for an easy, low-cost installation and makes the filter changing process a simple activity. Ellis Fibre USA also claims that when installed in an exhaust hood the GLS will significantly reduce the amount of grease that enters the exhaust system while also providing safety, operational, financial and environmental benefits (See Table 3).
The Investigation
The Applebee's Restaurant in Murrieta, California was selected for installation of the Grease Lock System. Area Director, Damasio Alvarez and General Manager, Loretta Cochneuer, were responsible for overseeing the investigation and reporting the results to Market President, Mike Hebert.
To begin the investigation, the current processes employed by Applebee's were monitored to determine the actual operational and financial impact of the activities (see Tables 1 and 2).
The exhaust hood at the Murrieta location was manufactured by Greenheck and consisted of two hoods sections located side-by-side. The listed metal baffle grease filters that were used prior to the installation of the GLS were the specialty Greenheck Grease X-Tractor Centrifugal Filter. They were all in poor condition and it was time for replacement. A basic UL listed baffle-type grease filter was used for the replacement, resulting in a significant cost savings over the prior filter type that was being used. One hood section was 120" wide and the other section was 132" wide. One technician completed the GLS installation process in less than 3 hours. The disposable replacement grease filters, known as Grease Lock Filters ("GLF") are all a standard 20" width and the installation at Murrieta contained a total of 12 disposable filters placed across the face of the hood aperture. (Note: the GLS and GLF are installed upstream or in front of the existing metal grease filters. The traditional metal grease filters remain installed in the hood system.)
Because the GLS is positioned upstream of the exhaust ducts/grease baffle filters, it can capture the grease particulates prior to them reaching the metal filters or entering the exhaust system. This is extremely important because the result of capturing grease particulates prior to them ever reaching the listed metal grease filters can result in a significant reduction in water consumption and the frequency of the nightly cleaning of the metal baffle grease filters. In fact, during the investigation, the cleaning of the metal baffle grease filters was reduced from every night to only once per month.
The investigation of on-going performance of the GLS was planned to last for 3 months. However, many of the benefits claimed by the GLS were confirmed within the first 48 hours of putting the system in place. All benefits claimed by the GLS were positively confirmed throughout the entire investigation (see Table 3).
Sustainability
The AAG is very proud of the steps is has taken to promote sustainability within its restaurants and the GLS is another product that fits well with the AAG goals in this area.
While the benefits of using the GLS include many things that have a direct cost savings impact, the GLS also is very earth-friendly. The disposable GLF is an all-natural, sustainable product that is 100% biodegradable. Additionally, using the GLS results in a significant reduction in water consumption as well as cleaner exhaust air being discharged into the atmosphere. Also, with less baffle filter cleanings being required to manage your hood, the grease being discharged down the drain into the municipal waste water system is dramatically reduced which could also reduce the frequency of pumping grease traps. Any organization interested in promoting sustainable initiatives will be very happy with the GLS. The investigation by AAG of using the GLS results in reduction in water consumption of over 12,500 gallons, annually per store. If implemented throughout the 1,950 Applebee's restaurants the GLS would save over 24,400,000 gallons of water, annually!
Conclusion
The overall cost/benefit analysis of the Grease Lock System at the Apple American Group reflects an expected savings of over $2,000/per store annually and a 100% Return on Investment in less than 3 months. This is a total savings of over $400,000 annually for just the Apple American Group franchise.
AAG Area Director, Damasio Alvarez offered "...aside from the obvious financial savings and operation benefits, the piece of mind that comes with knowing that your exhaust system is much cleaner year-around is invaluable. How do you put a price on piece of mind? As a multi-unit operator, knowing that all locations are obtaining the consistent benefit of cleaner ducts year-around is important."
Loretta Cochneuer, the AAG General Manager that was directly responsible for overseeing the investigation at the Murrieta location, was asked to discuss her thoughts on how the system performed, she states, "..the night staff is much happier not having to remove and clean the metal baffle filters every night. But, most of all the Grease Lock System saves me money on the bottom line and it is much easier than our prior practices with better performance!"
In summary, the investigation by the Southern California and Nevada Region of AAG has confirmed that the benefits promoted in Table 3 are realized when the GLS is installed at their locations. In fact, after three months of investigation, Mike Hebert ordered the installation of the GLS in all Applebee's locations within the region and is now receiving the benefits at all locations!
Have you examined the true cost of your exhaust system cleaning and maintenance process? Look into disposable grease filters to Stay a Step Ahead?
Joe Salpietra, Director, Ellis Fibre USA, has more than 20 years of experience serving the Food Service industry. He can be reached at 318.560.7417 or joe.salpietra@ellisfibreUSA.com. Visit Ellis Fibre USA at RFMA 2010 Booth #122.
| Table 1 Some of Applebee’s Typical Exhaust System Maintenance Activities: |
|---|
| - Nightly removal and cleaning of all listed baffle grease filters |
| - Nightly wipe-down of the interior of the hood canopy |
| - Nightly cleaning of area behind the listed baffle grease filters |
| - Quarterly 3rd party Exhaust System Cleaning |
| Table 2 AAG Cost drivers related to Hood Cleaning & Maintenance Activities: |
|---|
| - 3rd Party Hood Cleaning (4x/year) |
| - Labor costs associated with nightly hood cleaning activities |
| - Water Consumption from nightly hood cleaning activities |
| - Water consumption during quarterly hood cleaning activities |
| - Degreaser/Chemicals used during nightly hood cleaning activities |
| - Electricity used to heat water used for nightly hood cleaning activities |
| - Increased risk of workers comp injuries related to nightly hood cleaning |
| - Increased roof maintenance due to roof traffic associated with hood cleaning |
| Table 3 Benefits of using the Grease Lock System |
|---|
| - Reduce water consumption |
| - Reduce risk of fire in the kitchen exhaust system |
| - Cleaner air emissions to atmosphere |
| - Cleaner water discharge to municipal waste system |
| - Reduce risk of employee injuries |
| - Saves energy |
| - Reduce roof maintenance |
| - Saves money |