5A

- 1 APPEN DIX 5A

. ENGINEERING ANALYSIS

5A.1 INTRODUCTION

DOE used the Energy

- efficient Refrigerator Analysis Program (ERA) , further described

in Appendix 5B, to calculate energy use for baseline and energy

- saving configurations for cooled

cabinets and hybrid refrigeration products. Inputs to this program were generated from reverse

engineering teardowns of select cooled cabinet models. The values for the input variables to

ERA are shown in tabular format in Section 5A.2

.

One of the inputs to ERA was the U

- value of the glass door. DOE used the WINDOW 6

software to calculate the U

- values of its baseline, medium

- tech, and max

- tech glass doors. The

values for the input variables to WINDOW are also shown in tabular format in Section 5A.2

.

The incremental cost curves describing costs to attain each analyzed efficiency level are

based on the energy use output from the ERA program. Development of costs for these curves is

described in C hapter 5. The table s in S ection 5 A.3 show these incremental cost curves in tabular

format, with identification of the design options required to reach each efficiency level shown.

As part of the engineering analysis, DOE solicited input from manufacturers on a range

of technical topics affecting energy use in refrigeration products. The questionnaire used to

facilitate these i nterviews is shown in S ection 5 A.4.

5 A.2 ERA INPUTS

The ERA inputs for each of the units selected for reverse

- en gineering analysis are shown

below. Some general notes regarding the data include the following:

1) The ERA input for door openings is not provided, since DOE conducted analysis

based on closed doors.

2) DOE conducted all analyses using single evaporator syste m configuration with HFC

134a refrigerant.

3) The tube and fin heat exchanger configuration implies forced convection air flow.

4) See the Windows ERA program for definitions of air flow directions for forced

convection wire fin condensers.5A

- 2 Table 5A

. 1 ERA Inputs for Cooled Cabinets

Wine Chillers 6 ft 3

Baseline 6 ft 3 Middle

Unit 6 ft 3 Max

Available 6 ft 3 Max

Tech

General Data

Layout Upright

Freezer Upright

Freezer Upright

Freezer Upright

Freezer

Cabinet Dimensions

Height of insulated cabinet (cm) 77.79 74.93 77.47 77.47

Width of insulated cabinet (cm) 60.96 60.64 62.23 62.23

Depth from door flange (cm) 52.71 53.02 49.23 49.23

Depth from door outer surface (cm) 55.06 54.92 52.71 52.71

Liner Properties

Outer liner thickness (mm) 0.51 0.64 0.76 0.76

Outer liner conductivity (W/m

- K) 44.7 44.7 44.7 44.7

Inner liner thickness (mm) 1 2.08 4.39 4.39

Inner liner conductivity (W/m

- K) 0.16 0.16 0.16 0.16

Compressor Compartment

Dimensions

Height of compartment (cm) 12.7 6.35 5.72 5.72

Wall thickness (cm) 3.81 5.08 5.08 5.08

Top depth of compartment (cm) 9.53 15.88 18.42 18.42

Wall thickness (cm) 4.45 3.81 5.08 5.08

Bottom depth of compartment (cm) 9.53 15.88 18.42 18.42

Rated Food Storage Volume

Storage volume (L) 162 166 167 167

Cabinet Insulation

Top wall (cm) 4.45 3.81 5.08 5.08

Side wall (cm) 3.81 3.81 5.08 5.08

Back wall (cm) 4.45 3.81 5.08 5.08

Bottom wall (cm) 3.81 5.08 5.08 5.08

Insulation Resistivity

Top wall (m 2

- K/W

- cm) 0.5 0.5 0.5 1.09

Side walls (m 2

- K/W

- cm) 0.5 0.5 0.5 0.5

Back wall (m 2

- K/W

- cm) 0.5 0.5 0.5 1.0 9

Bottom wall (m 2

- K/W

- cm) 0.5 0.5 0.5 1.09

Door Flange

Flange width (cm) 3.81 3.81 5.08 5.08

Wedge depth (cm) 0 0 0 0

Resistivity (m 2

- K/W

- cm) 0.5 0.5 0.5 0.5

Heat Paths

Gasket heat leak (W/m

- 100K) 11 11 22 22

Cabinet penetration heat leak (W) 0 0 0 0

Door Properties

Door type Glass Glass Glass Glass5A

- 3 Door overall U

- value (W/m 2

- K) 3.044 3.044 1.709 1.143

Door Opening Schedule

Room relative humidity (%) 50 50 50 50

Cabinet door openings per hour 0 0 0 0

Average time door open (s) 20 20 20 20

Temperatures

Room air (C) 32.2 32.2 32.2 32.2

Under cabinet (C) 32.2 32.2 32.2 32.2

Air entering condenser (C) 32.2 32.2 32.2 32.2

Compressor compartment (C) 32.2 32.2 32.2 32.2

Cabinet (C) 12.8 12.8 12.8 12.8

Defrost Parameters

Defrost type Manual Manual Manual Manual

Cycle

- Dependent Controls Use

Outside the cabinet (W) 0 0 0 0

Inside the cabinet (W) 0 0 1.3** 0

Constant Controls Use

Outside the cabinet (W) 0 0 0 1.5

Inside the cabinet (W) 0 0 0 0

Anti

- Sweat Heat

Heat source N/A N/A N/A N/A

Cycle Parameters

Cycling losses: cycles/hr 0.25 2.25 0.85 0.36

Refrigerant R134a R134a R134a R134a

Freezer Evaporator

Exit superheat (C) 0.5 0.5 0.5 0.5

Evaporator type Coldwall Coldwall Coldwall Fan

- Forced,

Plain Fin

Fan Design

Rated fan power (W) N/A N/A N/A 1.8

Rated airflow rate (L/s) N/A N/A N/A 20

Coldwall Evaporator Design

Parameters

Tube OD (mm) 7.29 8 8 N/A

Tube wall thickness (mm) 0.762 0.813 0.813 N/A

Liner thickness (mm) 1.524 1.524 1.524 N/A

Liner conductivity (W/m

- K) 202 202 202 N/A

Back Wall

Area of wall (m 2 ) 0.17 0.26 0.2 N/A

Number of tube legs 10 16 18 N/A

Width normal to tubes (cm) 38.1 54.61 44.5 N/A

Tube and Fin Evaporator Design

Parameters

Tube OD (mm) N/A N/A N/A 7.94

Tube wall thickness (mm) N/A N/A N/A 0.815A

- 4 Width of tube row (cm) N/A N/A N/A 37.5

Number of rows normal to airflow N/A N/A N/A 9

Pitch (cm) N/A N/A N/A 4.17

Number of rows deep N/A N/A N/A 2

Pitch (cm) N/A N/A N/A 1.27

Fin Data

Fin thickness (mm) N/A N/A N/A 0.18

Fin pitch (mm) N/A N/A N/A 4.8

Fin thermal conductivity (W/m

- K) N/A N/A N/A 202

Fraction of tube width finned N/A N/A N/A 0.9

Condenser Design

Exit subcooling (C) 0.5 0.5 0.5 0.5

Heat exchanger configuration Tube/fin Tube/fin Tube/fin Tube/fin

Air

- side fin configuration Wire Herringbone Herringbone Herringbone

Fan Design

Rated fan power (W) 6 25 9 2.7

Rated airflow rate (L/s) 25 53 25 25

Wire and Tube Condenser Design

Airflow direction W N/A N/A N/A

Tube OD (mm) 4.72 N/A N/A N/A

Tube wall thickness (mm) 0.76 N/A N/A N/A

Length of tube along L direction

(cm) 15.37 N/A N/A N/A

Number of tubes along H direction 5 N/A N/A N/A

Pitch (cm) 2.86 N/A N/A N/A

Number of tubes along W direction 6 N/A N/A N/A

Pitch (cm) 2.22 N/A N/A N/A

Fraction of air through exchanger 0.8 N/A N/A N/A

Wire Fin Data

Wire diameter (mm) 1.32 N/A N/A N/A

Number of wires on one side 128 N/A N/A N/A

Wire length (cm) 13 N/A N/A N/A

Wire thermal conductivity (W/m

- K) 44.7 N/A N/A N/A

Wires on two sides? Yes N/A N/A N/A

Fin and Tube Condenser Design

Tube OD (mm) N/A 9.525 7.84 7.84

Tube wall thickness (mm) N/A 0.254 0.254 0.254

Width of tube row (cm) N/A 18.4 31.75 31.75

Number of tubes normal to airflow N/A 7 3 3

Pitch (cm) N/A 2.54 2.54 2.54

Number of tubes along W direction N/A 2 3 3

Pitch (cm) N/A 2.54 2.22 2.22

Fraction of air through exchanger N/A 0.8 0.8 0.8

Fin Data

Fin thickness (mm) N/A 0.13 0.15 0.155A

- 5 Fin pitch (mm) N/A 3.97 2.79 2.79

Fin thermal conductivity (W/m

- K) N/A 202 202 202

Fraction of tube width finned N/A 0.7 0.88 0.88

Fin pattern depth (mm) N/A 1 1.2 1.2

One

- half wavelength (mm) N/A 1.5 3 3

Compressor

Compressor map EMU30HSC EMU30HSC EMU30HSC VEMY3H

Capacity multiplier 1 1 1 1

Power multiplier 1.63 1.53 1 1

Speed multiplier 1 1 1 1

Interchanger

Effectiveness 0.8 0.8 0.8 0.9

Component Adjustment Factors

Evaporator UA 1 2.5* 3.5*** 1

* This scaling factor approximates the additional cooling capacity provided by a rollbond evaporator as compared to

the traditional coldwall evaporat or used by the baseline unit. In the version of ERA used for this modeling work,

r ollbond evaporators cannot currently be directly modeled.

** This controls energy usage represents the energy consumption of the max

- available unit’s evaporator fan.

*** This scaling factor approximates t he additional cooling capacity provided by utilizing an evaporator fan with a

rollbond evaporator. Such a configuration cannot currently be directly modeled in ERA.5A

- 6 Table 5A

. 2 WINDOW Inputs for Glass Doors

Glass Doors Baseline Medium

- Tech Max

- Tech

Cabinet Conditions

Air Temp (C) 12.8 12.8 12.8

Convection Model ASHRAE/NFRC ASHRAE/NFRC ASHRAE/NFRC

Radiation Model ASHRAE/NFRC ASHRAE/NFRC ASHRAE/NFRC

Effective Temp (C) 12.8 12.8 12.8

Effective Emissivity 0.9 0.9 0.9

Ambient Conditions

Air Temp (C) 32.2 32.2 32.2

Convection Model ASHRAE/NFRC ASHRAE/NFRC ASHRAE/NFRC

Radiation Model ASHRAE/NFRC ASHRAE/NFRC ASHRAE/NFRC

Effective Temp (C) 32.2 32.2 32.2

Effective Emissivity 0.9 0.9 0.9

Dimensions

Height (mm) 704.85 704.85 704.85

Width (mm) 552.45 552.45 552.45

Glass 1

ID 5010 4347 7200

Name CLEAR_4.ppg PlanibelG_4.pvb PlanibelG_3.afd

Thickness (mm) 3.9 3.8 3.1

Gap 1

ID 1 2 3

Name Air Argon Krypton

Thickness (mm) 11.2 11.2 4.8

Glass 2

ID 5010 4347 7200

Name CLEAR_4.ppg PlanibelG_4.pvb PlanibelG_3.afd

Thickness 3.9 3.8 3.1

Gap 2

ID N/A N/A 3

Name N/A N/A Krypton

Thickness (mm) N/A N/A 4.8

Glass 3

ID N/A N/A 7200

Name N/A N/A PlanibelG_3.afd

Thickness N/A N/A 3.1

Resultant U

- Value 3.044 1.709 1.1435A

- 7 5 A.3 Incremental Cost Detail

The tables in this section identify the groups of design options and their associated

manufacturer production costs for all analyzed efficiency levels for the reverse

- engineering units

for which the full incremental cost analysis was conducted.

Table 5A

. 3 Incremental Cost Detail for 6 ft 3 Cooled Cabinets

Efficiency Level Design Change Added Cost

Baseline ( 103 %) N/A $0

Middle

Efficiency ( 75 %) Conversion from coldwall to rollbond evaporator $ 4.51

Increase in compressor EER from 3 to 3.2 $ 2.15

Conversion from wire

- tube to fin

- tube condenser $ 14.35

Increase in condenser fan shaft power (from 1.5 W to 5 W) $ 3.88

Total Added Cost 75% vs. 10 3% $ 24.89

Max

- Available

( 48 %) Reduced size rollbond evaporator

- $1. 29

Adding evaporator fan $ 5.79

Increase in compressor EER from 3.2 to 4.9 $ 21.82

Improved dual

- pane glass door (low

- e coating, argon filling

, 4 ft 3 face area, 0.75” thick ) $12.00

Increased insulation thickness from 1.5” to 2” on top, sides,

and rear (bottom surface already had 2” of insulation). This

cost estimate does not include conversion costs. $3. 66

Change in con denser design . (Original: 7 by 2 row tube

configuration, 7.25” tube length, 0.375” tube diameter. New:

3 by 3 row tube configuration, 12.5” tube length, 0.31” tube

diameter.) $ 1.74

Smaller condenser fan, decrease in fan motor shaft power

(from 5 W to 1 W) - $ 3.86

Total Added Cost 48 % vs. 75 % $ 39.86

Max

- Tech ( 32 %) Conversion from rollbond to forced

- convection evaporator $ 5.77

Conversion from 12 V evaporator fan motor (0.5 W shaft

power) to brushless DC fan motor (1 W shaft power) $6.02

Conversion to variable

- speed compressor (Embraco

VEMY3H) $59.25

Improved glass door (triple

- pane, low

- e coating, krypton

filling) $18.00

Implementation of vacuum

- insulated panels (VIPs) on one

half of cabinet surface area $ 46.27

Conversion to brushless DC condenser fan motor $4.39

Total Added Cost 32 % vs. 48 % $ 139.69

Overall Added Cost 32% vs. 10 3% $ 204.445A

- 8 Table 5A

. 4 Incremental Cost Detail for 2 ft 3 Cooled Cabinets

Efficiency Level Design Change Added Cost

Baseline

Thermoelectric

( 267 %) N/A $0

Baseline Vapor

Compression

( 87 %) Conversion from thermoelectric to vapor

- compression

refrigeration system $ 64.47

Decrease in insulation thickness from 2” on all sides to 1” on

all sides ($6.27)

Total Added Cost 87 % vs. 267 % $58.20

Middle

Efficiency (7 5%) Increased insulation thickness from 1” on all sides to 1.5” on

top, sides, and rear and 2” on bottom $3.19

Increase in compressor EER from 3 to 3.2 $ 2.15

Conversion from wire

- tube to fin

- tube condenser $ 14.35

Increase in condenser fan shaft power (from 1.5 W to 5 W) $ 3.88

Total Added Cost 75 % vs. 87 % $ 23.57

Max

- Available

( 48 %) Adding evaporator fan $ 4.77

Increase in compressor EER from 3.2 to 4.9 $ 21.82

Improved dual

- pane glass door (low

- e coating, argon filling

, 4 ft 3 face area, 0.75” thick ) $ 5.33

Increased insulation thickness from 1.5” to 2” on top, sides,

and rear $3. 08

Change in condenser design . (Original: 7 by 2 row tube

configuration, 7.25” tube length, 0.375” tube diameter. New:

3 by 3 row tu be configuration, 12.5” tube length, 0.31” tube

diameter.) $ 1.74

Smaller condenser fan, decrease in fan motor shaft power

(from 5 W to 1 W) - $ 3.86

Total Added Cost 48 % vs. 75 % $ 32.88

Max

- Tech ( 32 %) Conversion from rollbond to forced

- convection evaporator $ 6.39

Conversion from 12 V evaporator fan motor (0.5 W shaft

power) to brushless DC fan motor (1 W shaft power) $6.02

Conversion to variable

- speed compressor (Embraco

VEMY3H) $59.25

Improved glass door (triple

- pane, low

- e coating, krypton

filling) $ 7.99

Implementation of vacuum

- insulated panels (VIPs) on one

half of cabinet surface area $ 26.47

Conversion to brushless DC condenser fan motor $4.39

Total Added Cost 32 % vs. 48 % $ 1 10.50

Overall Added Cost 32 % vs. 267 % $ 225.155A

- 9 Table 5A

. 5 Incremental Cost Detail for Portable Ice Makers

Efficiency Level Design Change Added Cost

Baseline

( 10 0 %) N/A $0

Max

- Available

(3 5 %) Adding insulation $0.66

Conversion from SPM to 12 V DC pump motor $0.69

Conversion from SPM to 12 V DC fan motor $0.45

Increase in compressor EER from 3.7 to 4.1 $5.05

Overall Added Cost 35 % vs. 10 0 % $6.85

Table 5A

. 6 Incremental Cost Detail for Cooled

- Storage Ice Makers

Efficiency Level Design Change Added Cost

Baseline

( 10 0 %) N/A $0

Max

- Available

( 74 %) Increase in evaporator surface area $4.98

Change in condenser design, from fin

- tube to extruded

aluminum $0.55

Increase in compressor EER from 3.5 to 4.1 $7.57

Overall Added Cost 74 % vs. 10 0% $ 13.10

Table 5A

. 7 Incremental Cost Detail for Uncooled

- Storage Ice Makers

Efficiency Level Design Change Added Cost

Baseline

( 10 0 %) N/A $0

Max

- Available

(63 %) Conversion from SPM to 12 V DC fan motor $1.50

Conversion from SPM to 12 V DC pump motors $1.23

Decrease in compressor EER from 4.8 to 3.9 ($11.35)

Increase in condenser size (8x2 rows to 6x3 rows) $0.56

Conversion from ACIM

- style evaporator to slab evaporator

with heater wire cutters $13.63

Addition of transformer for AC

- DC conversion $12.17

Addition of plastic piece to insulate front of bin $0.97

Addition of extra liquid

- line heat exchanger $2.30

Overall Added Cost 63 % vs. 10 0% $ 21.015A

- 10 Table 5A. 8 Incremental Cost Detail for Non

- Compressor Refrigerators

Efficiency Level Design Change Added Cost

Baseline

( 100 %) N/A $0

Baseline with

Added Insulation

(82 %) Added insulation thickness (from 1.25” to 1.5” on sides, top,

bottom, and rear, and from 1” to 2.5” on door) $0.80

Max

- Available

(79 %) Larger DC “cold side” fan motor $0.05

Additional DC “hot side” fan motor $1.66

Larger “cold side” heat sink $0.11

Heat pipe $11.00

Total added cost 79% vs. 82% $12.82

Max

- Available

with Added

Insulation

(6 6 %) Added insulation thickness (from 1.5” to 2” on sides, top,

bottom, and rear) $0.82

Max

- Tech

(64 %) Use of vacuum

- insulated panels on 50% of surface area $14.73

Overall Added Cost 64 % vs. 10 0% $ 29.17

5 A.4 Engineering Questionnaire

1. PRODUCT TECHNICAL DESCRIPTIONS

The following series of exhibits and questions address technical characteristics of wine chiller

and miscellaneous refrigeration product s

WIN E CHILLER/BEVERAGE COOLER

1.1 Is it a challenge to design wine chiller products (vapor compression and/or non

- vapor

compression based technology) that meet the CEC and/or NRCAN wine chiller standards?

What design choices have you made to ensure compliance?

V

APOR C OMPRESSION C OOLING T ECHNOLOGY :

1.2 For vapor compression wine/beverage coolers with automatic defros t, do you use an electric

heater to achieve defrost for any of these units? If so, please separately provide model

numbers and estimated shipment levels for this sub

- category of products.

Compressors :5A

- 11 1.3 Do you use different compressor types and sizes for various capacities and types of

wine/beverage cooler s (single zone and double zone)?

1.4 Wine/beverage cooler s generally use low

- back pressure hermetic reciprocating compressors.

Does the type of compressor to use depend on product type?

1.5 Do any of your products currently use variable

- speed compressors? If so, in what produc t

types and sizes do you use variable

- speed compressor. What is the cost premium of using a

variable

- speed compressor over a baseline ef ficiency single

- speed compressor?

1.6 If you do not employ variable

- speed compressors in your product , what are the technological

barriers to implementing this technology?

Please comment on the typical compressors used in your product

1.7 How does the nominal EER of the typical compressors used in your wine /beverage coolers

vary with compressor capacity ?

1.8 How do actual operating conditions of the compressor differ from the rating conditions?

1.9 Do you use a thermostatic expansion valve or capillary tube for your refrigerant flow control

device? Any use of EEV?

1.10 Do you use refrigerants other than R

- 134 in your wine /beverage coolers?5A

- 12 1.11 What compressor brand do you use in your wine /beverage coolers ? Are there other brands

that you may consider for these products?

Condenser and Evaporator Heat Exchanger:

1.12 Does your company use any air

- cooled condenser design other than round copper tube

aluminum fin?

1.13 What is the typical fin style, fin thickness and fin pitch (number of fins per inch)?

1.14 What is the typical copper tub e outer dimension? Do you use any internally enhanced tube?

1.15 What are the limitations on fin spacing associated with potential clogging? How does the

performance of the condenser degrade due to dirt?

1.16 What impact on system performance will increasing the s urface area of the condenser have?

Describe the design constraints associated with increasing the surface area of the condenser.

1.17 Is there a relationship between typical condenser airflow rate and compressor capacity? If so,

can you describe it?

1.18 Do you d esign and build the heat exchangers used in your product in

- house or do you

purchase them from an outside vendor?

1.19 What percentage of your wine /beverage cooler s uses more than one evaporator?

1.20 Do all your wine /beverage cooler s employ forced conve ct ion evap orators?

1.21 Does your evaporator use internally enhanced tubes?

Condenser Fan Motor:

1.22 What is the typical fan motor type (SPM, PSC, and ECM) used on your wine/beverage

coolers and ice makers?5A

- 13 1.23 What is the cost premium associated from changing your fan motor from one type to

another? For example from SPM to PSC, and from PSC to ECM

1.24 Is there room for measurable improvement via improved fan blade designs?

1.25 Is there any room for measurable improvement via improved airflow path design?

1.26 If you use variable speed compressors in your product , what type of condenser fan motor do

you use? Do you run the fan at multiple speeds to match the various mode of the compressor

operation? How would the energy consumption of the fan compare to a standard SPM or

ECM?

N

ON

- COMP RESSOR COOLING TECHNOLOGY:

1.27 What refrigeration system technology do your products use?

1.28 What is the COP range of your products refrigeration systems?

a) Wine Chiller:

b) Refrigerator:

1.29 What is the design range of ambient temperatures for your products?

1.30 Can the efficiency of the refrigeration system be improved with the following designs ? What

is the cost impact of such efficiency improvements?

a) Larger heat exchangers:

b) Forced convection vs. natural convection:

c) Better TE module:

d) Intermediate heat transfer flui d:

e) Higher efficiency fans:

1.31 Does any of your refrigerator products use defrost cycle ? Any wine chillers?

1.32 Is the absence of the compressor a key sales feature for your customers? Why or why not?

What other unique characteristics of your products are prefe rred by your customers?5A

- 14 I CE MAKERS

1.33 What are the harvest capacity (lb/day) ranges of the ice makers you produce?

1.34 Do you use a standard test procedure to verify the harvest capacity? If so what are the test

conditions?

1.35 Does your machine make ice by freezing water directly on the evaporator or by freezing the

water with cold air?

Ice Makers Compressors:

1.36 W hat types and capacity of compressors are used for different types and capacities of your

ice makers?

1.37 Do you generally use low

- back pressure herme tic reciprocating compressors? Does the type

of compressor to use depend on product type?

1.38 Does any of your product currently use variable

- speed compressors? If so, in what produc t

types and sizes do you use variable

- speed compressor. What is the cost prem ium of using a

variable

- speed compressor over a baseline efficiency single

- speed compressor?

1.39 How does the nominal EER of the typical compressors used in your ice makers vary with hp?

1.40 How do actual operating conditions of the compressor differ from the rating conditions?

1.41 Do you use a thermostatic expansion valve or capillary tube for your refrigerant flow control

device? Any use of EEV?

1.42 Do you use refrigerants other than R

- 134 in your ice makers?

1.43 What compressor brand do you use in your ice makers ? Are there other brands that you may

consider for these products?5A

- 15 Ice Maker Pumps (if applicable):

1.44 What type of pump d o you use in your ice makers? What is typical rpm of the pumps? What

make of pump and/or pump motor do you use?

1.45 What is the typical motor type used in your pumps?

Ice Maker Evaporators/ Cube Mold:

1.46 Briefly describe your evaporator design, its geometry and materials used. Do you use

evaporators with internal enhanced tube?

1.47 How many distinct evaporator designs does your company produ ce?

1.48 Is there an optimum rate of water circulation during the icemaking cycle? Is there a “rule of

thumb” for circulation rate as a function of icemaking rate?

1.49 Has your company actively pursued any developments in recent years to improve evaporator

perfor mance, to improve heat transfer to the freezing surface during the icemaking cycle,

improve heat transfer and/or focus heat addition to critical locations for harvest?

R EFRIGERATOR C ABINET I NSULATION C HARACTERISTICS :

1.50 What type of insulation do you use i n your wine/beverage coolers and ice makers ? What is

the typical insulation thickness ?

1.51 What blowing agent do you use in your insulation system?

1.52 Have you considered other blowing agents other HFC

- 24fa? If so, what are the conductivity

and cost impact of these other blowing agents?

1.53 How would the following design help improve the insulation of your product?

a) Gaskets design:

b) Glass door design :

i) Number of panes:

ii) Low

- E coating:

iii) Gases for lower th ermal transmission (e.g Argon):5A

- 16 1.54 Do you offer wine/beverage cooler s with solid doors? How does the performance of

wine/beverage cooler with solid door differ from that with transparent doors?

1.55 For your wine/beverage coolers equipped with transparent doors, do you manufacturer the

doors in

- house or purchase from an outside vendor?

2. COMPONENT PARTS AND MATERIAL COSTS

In the following tables, we have compiled estimates for components pricing at h igh

- volume

manufacturing (i.e., 100,000+ units per year). These estimates are based on a number of different

sources, most of which are not component suppliers. They are estimates and should NOT be

construed as actual quotes for component and raw material prices. Please provide feedback

regarding the likely raw material and purchased part costs for the items below.

Table 2.1 Fan Motor Cost Estimates, as of 5/2012

Description Cost

($/ea) Manufacturer

Comments

3W Shaded pole motor $3.85

5W Shaded pole motor $4.74

9W Shaded pole motor $5.25

12W Shaded pole motor $5.27

Note: Power rating is electric power

Table 2.2 Compressor Cost Estimates, as of 5/2012

Description Cost

($/ea) Manufacturer

Comments

232 BTU; 3.17 EER $24

337 BTU; 3.75 EER $30

365 BTU; 4.4 EER $34

494 BTU; 4.85 EER $39

494 BTU; 5.56 EER $44

512 BTU; 4.7 EER $35

Note: Compressor information at rating condition. T Cond = 130 o F, T Evap =

- 10 o F

2.1 The following chart shows DOE’s assumption for raw material prices for common metals

found in wine/beverage cooler and ice makers. Please assume the delivery price at the

shipping dock of your facility, inclusive of all processing costs, shipping costs, et c.

Table 2.3 Metal Cost Estimates, as of 5/20125A

- 17 Metals Cost ($/lb)

As of 5/2012 Manufacturer Feedback

Aluminized Cold Rolled Steel $0.533

Galvanized Cold Rolled Steel $0.531

Textured CRS $0.674

Stainless Steel 304 $1.600

Plain Cu Tube, ≤0.75” OD $4.292

Fin Aluminum $1.444

2.2 For plastics, DOE assumed that most parts are made in

- house, in a variety of injection

molding machines. The table below is DOE’s assumption for common plastics found in

wine/beverage cooler and ice makers. Please indicate how the following prices compare to

your raw material costs.

Table 2.4 Non

- Metal Raw Material Cost Estimates, as of 5/2012

Resin Cost ($/lb)

As of 5/2012 Manufacturer Feedback

High Impact Polystyrene

(HIPS) $1.210

Acetal (POM) $1.282

Polyurethane Foam $1.613

Refrigerant Gas

– R134a $2.131

Tempered Glass $0.517

3. FACTORY PARAMETER ASSUMPTIONS

DOE used information gathered from its analysis of common industry practices to formulate

factory parameters for manufacturers. Please comment on the following factory parameter

assumptions.5A

- 18 Parameter Estimate for

Wine/beverage

coolers Manufacturer

Feedback Estimate

for Ice

Makers Manufacturer

Feedback

Actual Annual

Production Volume

(units/year)

Work Days Per Year

(days)

Assembly Shifts Per Day

(shifts)

Fabrication Shifts Per

Day (shifts)

Fabrication Labor Wages

($/hr)

Assembly Labor Wages

($/hr)

Fringe Benefits Ratio

Burdened Assembly

Labor Wage ($/hr)

Supervisor Span

(workers/supervisor)

Supervisor Wage

Premium (over

fabrication and assembly

wage)

Indirect to Direct Labor

Ratio

Length of Shift (hrs )

Average Worker

Downtime per shift

Average Equipment

Installation Cost (% of

purchase price)

Average Scrap Recovery

Value (using base

material value)

Building Life (in years)