3

- i CHAPTER 3

. MARKET AND TECHNOLOGY ASSESSMENT

TABLE OF CO NTENTS

3.1 INTRODUCTION

................................ ................................ ................................ ........... 3

- 1

3.2 PRODUCT DEFINITION

................................ ................................ ............................... 3

- 1

3.3 PRODUCT CLASSES

................................ ................................ ................................ ..... 3

- 1

3.4 PRODUCT TEST PROCEDU RES

................................ ................................ ................. 3

- 2

3.5 MANUFACTURER TRADE G ROUPS

................................ ................................ ......... 3

- 2

3.6 MANUFACTURER INFORMA TION

................................ ................................ ........... 3

- 3

3.6.1 Manufacturers and Market Shares

................................ ................................ ................... 3

- 3

3.6.2 Mergers and Acquisitions

................................ ................................ ................................ 3

- 4

3.6.3 Small Business Impacts

................................ ................................ ................................ ... 3

- 6

3.6.4 Distribution Channels

................................ ................................ ................................ ...... 3

- 6

3.7 REGULATORY PROGRAMS

................................ ................................ ....................... 3

- 7

3.7.1 Federal Energy Conservation Standards

................................ ................................ .......... 3

- 7

3.7.2 Canadian Energy Conservation Standards

................................ ................................ ....... 3

- 8

3.8 VOLUNTARY PROGRAMS

................................ ................................ .......................... 3

- 9

3.8.1 Consortium for Energy Efficiency

................................ ................................ ................... 3

- 9

3.8.2 ENERGY STAR

................................ ................................ ................................ .............. 3

- 9

3.8.3 Federal Energy Management Program

................................ ................................ .......... 3

- 10

3.9 HISTORICAL SHIPMENTS

................................ ................................ ......................... 3

- 11

3.9.1 New Home Starts

................................ ................................ ................................ ........... 3

- 11

3.9.2 Unit Shipments

................................ ................................ ................................ ............... 3

- 11

3.9.3 Value of Shipments

................................ ................................ ................................ ........ 3

- 13

3.9.4 Imports and Exports

................................ ................................ ................................ ....... 3

- 15

3.10 HISTORICAL EFFICIENC IES

................................ ................................ ..................... 3

- 16

3.11 MARKET SATURATION

................................ ................................ ............................ 3

- 17

3.12 PRODUCT RETAIL PRICE S

................................ ................................ ....................... 3

- 18

3.13 INDUSTRY COST STRUCT URE

................................ ................................ ................ 3

- 21

3.14 INVENTORY LEVELS AND CAPACITY UTILIZATION RATES

.......................... 3

- 24

3.15 TECHNOLOGY ASSESSMEN T

................................ ................................ .................. 3

- 26

3.15.1 Dishwasher Operations and Components

................................ ................................ ...... 3

- 26

3.15.2 Dishwasher Technology Options

................................ ................................ ................... 3

- 28

3.15.3 Energy Efficiency

................................ ................................ ................................ .......... 3

- 35

LIST OF TABLES

Table 3.6.1 Major and Other Dishwasher Manufacturers

................................ ........................... 3

- 4 Table 3.7.1 Current Federal Energy Conservation Standards for Residential Dishwashers

...... 3

- 8 Table 3.7.2 Proposed Consensus Agreement Standards for Residential Dishwashers

............... 3

- 8

Table 3.8.1 CEE Criteria for Residential Dishwashers

................................ ............................... 3

- 93

- ii

Table 3.8.2 ENERGY STAR Qualifying Criteria for Residential Dishwashers

...................... 3

- 10

Table 3.9.1 New Privately Owned Single

- Family and Multi

- Family Housing Unit Starts

in the United States from 1998

– 2010 (Thousands)

................................ ........... 3

- 11

Table 3.9.2 Industry Shipments of Residential Dishwashers (Domestic and Import) ,

............ 3

- 12

Table 3.9 .3 ENERGY STAR Dishwasher Shipments and Market Share (Domestic and

Import)

................................ ................................ ................................ ............... 3

- 13 Table 3.9.4 Annual Shipment Value of Major Household Appliances , , , ,

............................... 3

- 14 Table 3.9.5 Annual Shipment Value of Other Major Household Appliances , , , , , , ,

.................. 3

- 15 Table 3.9.6 Disposition of Previous Dishwasher

................................ ................................ ...... 3

- 15 Table 3.9.7 Annual Dishwasher Imports/Exports

................................ ................................ ..... 3

- 16 Table 3.10.1 Annual Shipment

- Weighted Per

- Cy cle Dishwasher Energy Consumption ,

....... 3

- 17 Table 3.11.1 Percentage of U.S. Households with Dishwashers ,

................................ ............. 3

- 18 Table 3.12.1 Average Dishwasher Retail Prices

................................ ................................ ....... 3

- 19 Table 3.13.1 Major Appliance Manufacturing Industry Employment and Ea rnings

................ 3

- 21 Table 3.13.2 Other Major Home Appliance Industry Employment and Earnings

.................... 3

- 22 Table 3.13.3 Major Appliance Manufacturing Industry Materials and Wages Cost

................. 3

- 22

Table 3.13.4 Ot her Major Appliance Industry Materials and Wages Cost

................................ 3

- 23 Table 3.13.5 Industry Financials from Income Statement, Average 2003

– 2010

...................... 3

- 24 Table 3.13.6 Industry Financials from Cash Flow Statement, Average 2003

– 2010

................. 3

- 24

Table 3.13. 7 Industry Financials from Balance Sheet, Average 2003

– 2010

............................. 3

- 24 Table 3.14.1 Major Appliance Manufacturing Industry Inventory Levels

............................... 3

- 25 Table 3.14.2 Other Major Appliance Manufacturing Industry Inventory Levels

..................... 3

- 25

Table 3.14.3 Ful l Production Capacity Utilization Rates ,

................................ ........................ 3

- 26 Table 3.15.1 Technology Options for Residential Dishwashers

................................ ................ 3

- 28

LIST OF FIGURE S

Figure 3.6.1 2008 Market Shares for the Domestic Residential Dishwasher Market

................. 3

- 4 Figure 3.6.2 2008 Core Appliance Market Shares

................................ ................................ ...... 3

- 5 Figure 3.12.1 Standard

- Size Residential Dishw asher Retail Price as a Function of Annual

Energy Use

................................ ................................ ................................ ......... 3

- 20 Figure 3.12.2 Standard

- Size Residential Dishwasher Retail Price as a Function of Water

Consumption

................................ ................................ ................................ ...... 3

- 20 Figure 3.15.1 Standard Dishwashers in the CEC Directory

................................ ...................... 3

- 353-1 CHAPTER 3. MARKET AND TECHNOLOG Y ASSESSMENT

3.1 INTRODUCTION

This chapter provides a profile of the residential dishwasher industr y in the United States. The U.S. Department of Energy (DOE) develope d the market and technology assessment presented in this chapter primarily from publicly available information. This assessment is helpful in identifying the major manufacturers and their product characteristics, which form the basis for the engineering a nd the life

- cycle cost (LCC) analyses. Present and past industry structure and industry financial information help DOE in the process of conducting the manufacturer impact analysis.

3.2 PRODUCT DEFINITION

DOE defines “ dishwasher ” under the Energy Policy and Conservation Act (EPCA) of 1975 (42 U.S.C. 6291

– 6309) as “a cabinet

- like appliance which with the aid of water and detergent, washes, rinses, and dries (when a drying process is included) dishware, glassware, eating utensils, and most cooking utensils by chemical, mechanical and/or electrical means and discharges to the plumbing drainage system.” ( 10 CFR 430.2 )

3.3 PRODUCT CLASSES

DOE separate s dishwashers into two product classes. T he criteria for separation into

different classes are: (1) type of energy used, and (2) capacity or other performance

- related features such as those that provide utility to the consumer or others deemed appropriate by the Secretary that would justify the establishment of a separate energy conservation standard . (42 U.S.C. 6295(q) and 6316(a))

For dishwashers , the size of the unit significantly impacts the energy consumed. In other words, standard

- size dishwashers with relatively greater water consumption have significantly

greater energy use than compact units. Because standard dishwashers offer enhanced consumer utility over compact units ( i.e

., the ability to wash more dishes), DOE has establish ed the following product classes, which are based on the size of the dishwasher (as specified in

American Nati onal Standards Institute (ANSI)/Association of Home Appliance Manufacturers (AHAM) Standard DW

- 1

- 1992

, Household Electric Dishwashers ):

• Compact, ( capacity less than eight place settings plus six serving pieces ) ; and

• Standard, ( capacity equal to or greate r than eight place settings plus six serving pieces )

.3-2

3.4 PRODUCT TEST PROCEDU RES

DOE’s test procedure for dishwashers is found in the Code of Federal Regulations (CFR) at 10 CFR part 430, subpart B, appendix C. DOE originally established its test procedure for

dishwashers in 1977. 42 FR 39964 (Aug ust 3, 1977). In 1983, DOE amended the test procedure

to revise the representative average

- use cycles to reflect consumer use and to address

dishwashers that use 120 degree Fahrenheit ( °F ) inlet water. 48 FR 9202 ( Mar ch 3, 1983). DOE amended the test procedure again in 1984 to redefine “water heating dishwasher.” 49 FR 46533 (Nov ember 27, 1984)

. In 1987, DOE amended the test procedure to address models that use 50

° F inlet water. 52 FR 47551 (December 15, 1987). In 2001, DOE revised the test procedure’s testing specifications to improve testing repeatability, chang e the definitions of “compact dishwasher” and “standard dishwasher,” and reduc e the average number of use cycles per year

from 322 to 264. 66 FR 65091

, 65095

– 97 (Dec ember 18, 2001).

In 2003, DOE again revised the test procedure to more accurately measure dishwasher

efficien cy, energy use, and water use. The 2003 dishwasher test procedure amendments included the following revisions: (1) the addition of a method to rate the efficiency of soil

- sensing products; (2) the addition of a method to measure standby power; and (3) a reduction in the

average

- use cycles per year from 264 to 215. 68 FR 51887 , 51899

– 903 (August 29, 2003 ). The

current version of the t est procedure includes provisions for determining annual energy use expressed in kilowatt

- hours (kWh) per year , estimated annual operating cost, energy factor (EF) expressed in cycles per kWh, and water consumption expressed in gallons per cycle. (10 CFR

4 30.23) DOE is current ly considering amend ments to the test procedure to further address standby mode and off mode energy consumption.

3.5 MANUFACTURER TRADE G ROUPS

DOE recognizes the importance of trade groups in disseminating information and promoting the i nterests of the industry that they supp ort. To gain insight into the dishwasher industry , DOE researched various associations available to manufacturers, suppliers , and users of such equipment.

The Association of Home Appliance Manufacturers a (AHAM), fo rmed in 1967, aims to

e nh ance the value of the home appliance industry through l eadership, public education and advocacy. AHAM provides services to its members including government relations ; certification programs for room air conditioners, dehumidifiers and room air clean ers ; an active communications program ; and technical services and research. In addition, AHAM conducts other market and consumer research studies and publishes a biennial Major Appliance Fact

Book

. AHAM also develops and maintains technical standards for various appliances to provide uniform, repeatable procedures for measuring specific product characteristics and performance

features

.

a For more information, please visit www.aham.org

.3-3

3.6 MANUFACTURER INFORMA TION

The following section details information regarding manufacturers of dis hwashers, including estimated market shares (section 3.6.1 ), industry mergers and acquisitions (section

3.6.2 ), potential small business impacts (section 3.6.3 ), and product distribution channels (section 3.6.4 ).

3.6.1 Manufacturers and Market Shares

Using publicly available data ( e.g. , Appliance Magazine and market assessments done by third parties), DOE estimates the domestic market shares for di shwasher manufacturers

. Manufacturers may offer multiple brand names. Some of the brand names come from independent appliance manufacturers that have been acquired over time, and domestic manufacturers may put their brand on a pr oduct manufactured overse as.

For residential dishwashers , DOE estimates that there are approximately 1 8 manufacturers supplying the domestic market

. In 2008 (the most recent year for which market share data were available) , n early the entire market, or 94 percent, wa s controlled by three

dome stic manufacturers: Whirlpool, General Electric (G E )

, and AB Electrolux ( under the Frigidaire brand b ). The merger between Whirlpool and Maytag resulted in the c ombined company accounting for 49 percent of the domestic dishwasher market in 2008 . BSH Home Appliances Corporation account ed for five percent of the total market in 2008 , and the remaining one percent is made up of companies includi ng ASKO Appliances, Inc. ( ASKO ), Dacor Inc. (Dacor), Equator Corporation (Equator), Fagor America Inc. (Fagor), Fisher & Paykel Appliances Limited (Fisher & Paykel), Haier America Trading, LLC (Haier), Miele, Inc. (Miele), Viking Range Corporation (Viking) and others. More recently, AGA Rangemaster Group plc (AGA), Bonferraro SpA (Bonferraro), Foshan Shunde Midea Washing Appliances Manufacturing Company, Ltd. (Midea), Merloni Elettrodomestici (Merloni), Samsung

Electronics , Inc. (Samsung) and LG Electronics , Inc. (LG) have also entered the domestic

market. Table 3.6

. 1 lists these manufacturers. Figure 3.6

. 1 illustrates the 200 8 market shares for

the domestic residential dishwasher market.

b AB Electrolux also markets residential dishwashers in much smaller volumes under the Electrol ux brand.3-4

Table 3.6

. 1 Major and Other Dishwasher Manufacturers Major Manufacturers Other Manufacturers Whirlpool AGA

GE ASKO

Electrolux Bonferraro BSH Home Appliances

Dacor Equator Fagor

Fis her & Paykel

Haier

LG

Merloni

Midea

Miele Samsung Viking

Figure 3.6

. 1 2008 Market Shares for the Domestic Residential Dishwasher Market 1

3.6.2 Mergers and Acquisitions

Due to mergers and acquisitions, the home appliance industry continues to consolidate. While this phenomenon varies from product to product within the industry, the large market shares of a few companies provide evidence in support of this characterization.3-5

According to the January 20 10 Appliance Market Research Report

, three manufacturers comprise d 85 percent of the core major appliance market share in 2008

. The term “ c ore major appliance ” include s dishwashers, dryers, freezers, ranges, refrigerators, and clothes washers. Figure 3.6

. 2 200 8 Core Appliance Market Shares Figure 3.6

. 2 illustrat es the breakdown of 200 8 market shares in the core appliance category.

Figure 3.6

. 2 200 8 Core Appliance Market Shares 2

On August 22, 2005, Whirlpool, headquartered in Benton Harbor, Michigan , and Maytag, based in Newton, Iowa, announced plans to merge in a deal worth $2.7 billion. 3 Maytag shareholders approved the merge r on December 22, 2005. Shortly after announcing the merger, Whirlpool submitted a pre

- merger notification to the U.S. Depa rtment of Justice (DOJ). The DOJ Antitrust Division initiated an investigation, scheduled to end February 27, 2006, into the effects of the merger, including potential lessening of competition or the creation of a monopoly. Following this initial review, the DOJ asked for additional materials from each company and extended the review to March 30, 2006.

Opponents of the merger asserted that the combined companies would control as much as 70 percent of the residential laundry market and as much as 50 per cent of the residential

dishwasher market. 4 Whirlpool claimed that their large potential residential laundry market share was skewed because the company produces washing machines for Sears, which sells them

under their Kenmore in

- house brand. Whirlpool w ent on to say that they must periodically bid with other manufacturers to keep the Kenmore contract and that Sears controls the pricing of the

Kenmore units. 5

In early January 2006, U.S. Senator Tom Harkin and U.S. Representative Leonard Boswell, both of Iowa, called upon the DOJ to block the merger, claiming it would give Whirlpool an unfair advantage in the home appliance industry. The Congressmen wrote, that if the DOJ does not block the deal, the agency should at least “ require that Whirlpool divest t he3-6

washer and dryer portions of Maytag to a viable purchaser who will have the financial capability and desire to continue to operate that business .” 6

On March 29, 2006, DOJ closed its investigation and approved the merger. DOJ claims “that the proposed transaction is not likely to reduce competition substantially. The combination of strong rival suppliers with the ability to expand sales significantly and large cost savings and other efficiencies that Whirlpool appears likely to achieve indicates that t his transaction is not likely to harm consumer welfare.” 7

The DOJ Antitrust Division focused its investigation on residential laundry, although it considered impacts across all products offered by the two companies. DOJ determined that the merger would n ot give Whirlpool excessive market power in the sale of its products and that any attempt to raise prices would likely be unsuccessful. In support of this claim, DOJ noted : (1) other U.S. brands, including Kenmore, GE, and Frigidaire, are well established ; (2) foreign manufacturers, including LG and Samsung, are gaining market share; (3) existing U.S. manufacturers are below production capacity; (4) the large home appliance retailers have alternatives available to resist price increase attempts; and (5) Wh irlpool and Maytag substantiated large cost savings and other efficiencies that would benefit consumers. 8

Whirlpool and Maytag completed the merger on March 31, 2006. This large merger

followed several other mergers and acquisitions in the home applianc e industry. For example, Maytag acquired Jenn

- Air Corporation (Jenn

- Air) in 1982, Magic Chef, Inc. (Magic Chef) in 1986, and Amana Appliances (Amana) in 2001. Whirlpool acquired the KitchenAid division of Hobart Corporation (KitchenAid) in 1986. White C onsolidated Industries (WCI) acquired the Frigidaire division of General Motors Corporation in 1979, and AB Electrolux acquired WCI (and therefore Frigidaire) in 1986.

3.6.3 Small Business Impacts

DOE considers the possibility of small businesses being impacted by the promulgation of energy conservation standards. At this time, DOE is not aware of any small manufacturers, defined by the Small Business Association as having 500 employees or fewer, 9 who produce

dishwashers and who therefore would be impacted by a minimum efficiency standard.

3.6.4 Distribution Channels

Understanding the distribution channels of dishwashers is an important facet of the market assessment. DOE gathered information regarding the distribution channels fo r dishwashers fro m publicly availabl e sources.

The distribution chain for dishwashers, and most residential appliances, differs from commercial products, as the majority of consumers purchase their appliances directly from

retailers. These retailers include : (1) home improvement, appliance , and department stores; (2)

i nternet retailers; (3) membership warehouse clubs; and (4) kitchen remodelers. The AHAM3-7

2005 Fact Book reports that home improvement stores claim nearly one out of every four dollars spent on appliances. 10

Home appliance retailers generally obtain products directly from manufacturers. The

AHAM 2003 Fact Book shows that over 93 percent of residential appliances are distributed from the manufacturer directly to a retailer. 11

3.7 REGULATORY PROGRAMS

The following section details current regulatory programs mandating energy conservation

standards for dishwashers. Section 3.7.1 discusses Federal energy conservation standards

, and

section 3.7.2 review s standards in Canada that may impact the companies servicing the North

American market.

3.7.1 Federal Energy Conservation Standards

Current Federal standards exist for residential dishwashers . The National Appliance Energy Conservation Act of 1987 (NAECA) (42 U.S.C. 6291

– 6309) amended EPCA to establish prescriptive standards for dishwashers , requiring that they be equipped with an option to dry without heat and further requir ing that DOE conduct two cycles of rulemakings to determine if more stringent standards are justified. (42 U.S.C. 6295 (g)(1), (4) and (5)) On May 14, 1991, DOE issued a final rule establishing the first set of performa nce standards for dishwashers (56 FR 22250); those standards became effective on May 14, 1994. (10 CFR 430.32(f)) DOE initiated a second standards rulemaking for dishwashers by issuing an advance notice of proposed rulemaking (ANOPR) on November 14, 1994 . (59 FR 56423) However, as a result of the priority

- setting process outlined in its Procedures for Consideration of New or Revised Energy Conservation Standards for Consumer Products (the “Process Rule”) ( 61 FR 36974 (July 15, 1996); 10 CFR part 430, su bpart C, appendix A), DOE suspended the standards rulemaking

for dishwashers.

The Energy Independence and Security Act of 2007 c (EISA 2007) further amended

EPCA to establish new energy conservation standards for residential dishwashers manufactured

on o r after January 1, 2010

. (42 U.S.C. 6295(g)(10)(A); 10 CFR 430.32(f)(2)) The current standards established by the EISA 2007 amendments are shown below in Table 3.7

. 1

. The amendments also specify that not later than January 1, 2015, the Secretary shall publish a final rule determining whether to amend the standards for dishwashers manufactured on or after January 1, 2018. (42 U.S.C. 6295(g)(10)(B))

c Pub. L. 110

- 140 (enacted Dec. 19, 2007).3-8

Table 3.7

. 1 Current Federal Energy Conservation Standards for Residential Dishwashers

Dishwasher

Classification M aximum Annual Energy Use (kWh/year) Maximum Water Consumption (gallons/cycle) Compact dishwasher 355 6.5

Standard dishwasher 260 4.5

On July 30, 2010, AHAM and the American Council for an Energy Efficient Economy (ACEEE) , additionally representing manufacturers ( Whirlpool, GE , Electrolux, LG, BSH Home Appliances (BSH), Alliance Laundry Systems (ALS), Viking Range, Sub

- Zero Wolf, Friedrich
A/C, U

- Line, Samsung, Sharp Electronics, Miele, Heat Controller, AGA Marvel, Brown Stove, Haier, Fagor America, Airwell Group, Arcelik, Fisher & Paykel, Scotsman Ice, Indesit,

Ku ppersbusch, Kelon, and DeLonghi) ; ener gy and environmental advocates (Appliance Standards Awareness Project (ASAP), Natural Resources Defense Council (NRDC), Alliance to Save Energy (ASE), Alliance for Water Efficiency (AWE), Northwest Power and Conservation Council (NPCC), and Northeast Energ y Efficiency Partnerships (NEEP)); and consumer groups (Consumer Federation of America (CFA) and the National Consumer Law Center (NCLC))

submitted to DOE a multi

- product standards agreement (Consensus Agreement) that address es negotiated standards for mul tiple products, including residential dishwashers. Table 3.7

. 2 shows

the negotiated dishwasher standards from the Consensus Agreement

, with a proposed 2013 compliance date.

Table 3.7

. 2 Proposed Consensus A greement Standards for Residential Dishwashers

Dishwasher

Classification M aximum Annual Energy Use (kWh/year) Maximum Water Consumption (gallons/cycle) Compact dishwasher 307 5.0

Standard dishwasher 222 3.5

3.7.2 Canadian Energy Conservation Standards

Canada’s Energy Efficiency Regulations (hereafter Regulations) establish en ergy conservation standards for dishwashers

.

Canadian Regulations include maximum energy use requirements and definitions for

dishwashers that are identical to the current U.S. Fe deral standards , setting a maximum annual

energy use of 355 kWh/year for standard dishwashers and 260 kWh/year for compact

dishwashers. However, the Canadian Regulations do not include any requirements for water consumption.3-9

3.8 VOLUNTARY PROGRAMS

DOE review ed several voluntary progr ams promoting energy efficient dishwashers in the

United States . Many programs, including the Consortium for Energy Efficiency ( CEE )

, E NERGY STAR , and the Federal Energy Management Program (FEMP), establish voluntary

energy conse rvation standards for these products.

3.8.1 Consortium for Energy Efficiency

The CEE d develops initiatives for its North American members to promote the

man ufacture and purchase of energy efficient products and services. The goal of the organization is to indu ce lasting struc tural and behavioral changes in the marketplace, resulting in the increased adoption of energy efficient technologies

.

CEE issues voluntary specific ations for residential standard

- size and compact

dishwashers. Table 3.8

. 1 presents the dishwasher efficiency specifications, effective August 11

, 2009, under its Super

- Efficient Home Appliance Initiative (SEHA).

Table 3.8

. 1 CEE Criteria for Residential Dishwashers

Standard

- sized Dishwashers

Level Minimum EF Maximum kWh/yr Maximum gallons/cycle

Tier 1 0.72 307 5.00

Tier 2 0.75 295 4.25 Compact Dishwashers

Level Minimum EF Maximum kWh/yr

Tier 1 1.00 2 2 2 3.5 0

3.8.2 ENERGY STAR

ENERGY STAR, a voluntary labeling program backed by the U.S. Environmental Protection Agency ( EPA ) and DOE, identifies energy efficient products through a qualification

process. e To qualify, a product must exceed F ederal minimum sta ndards by a specified amount,

or if no F ederal standard exists, exhibit selected energy

- saving features. The ENERGY STAR program works to recognize the top quartile of products on the market, meaning that approximately 25 percent of products on the market should meet or exceed the ENERGY STAR

levels. E NERGY STAR specifications exist for several products, including dishwashers.

On August 11

, 200 9 , the current E NERGY STAR residential dishwasher qualifying

criteria took effect. The ENERGY STAR program establishes performance requirements for both standard and compact dishwashers. New criteria are set to take effect on January 20, 2012

. The current and future E NERGY STAR criteria for residential dishwashers are listed in Table

d For more information, please visit www.cee1.org

.

e F or more information, please visit www.energystar.gov

.3-10

3.8

. 2

. The 2012 ENERGY STAR qualifying criteria also include Tier 2 levels for both standard and compact dishwashers, and a possible cleaning performance requirement, but the maximum allowable energy and water use values for that tier have yet to be determined.

Table 3.8

. 2 ENERGY STAR Qualifying Criteria for Residential Dishwashers

Current Criteria Level s January 20, 2012 Tier 1 Criteria

Levels

Dishwasher

Classification Annual

Energy Use (kWh/year) Water

Consumption (gallons/cycle) Annual

Energy Use (kWh/year) Water

Consumption (gallons/cycle)

Standard

dishwasher 324 5.8 295 4.25

Compact

dishwasher 234 4.0 222 3.5

3.8.3 Federal Energy Management Program

DOE’s Federal Energy Management Program f (FEMP) works to reduce the cost and environmental impact of the Federal government by advancing energy efficiency and water conservation, promoting the use of distributed and rene wable energy, and improving utility management decisions at Federal sites

. FEMP helps Federal buyers identify and purchase

energy efficient equipment, including residential dishwashers.

FEMP issues energy efficiency recommendations for both standard

- size and compact

residential dishwashers. T he FEMP requirements for residential dishwashers are based on the current ENERGY STAR efficiency levels, shown in Table 3.8

. 2

. FEMP estimates a lifetime cost savings of $30 for a standard

- size dishwasher just meeting the FEMP requirements (and

therefore the EN ERGY STAR requirements) compared to a baseline dishwasher.

f For more information, please visit www.eere.energy.gov/femp

.3-11

3.9 HISTORICAL SHIPMENTS

Awareness of annual product shipment trends is an important aspect of the market assessment and in the development of the standards rulemaking. DOE reviewed data collected by the U.S. Census Bureau, EPA, and AHAM to evaluate residential dishwasher shipment trends and the value of these ship ments. Knowledge of such trends will be used during the shipments analysis ( c hapter 9 of this technical support document ( TSD ) ).

3.9.1 New Home Starts

Trends in new home starts may directly affect shipments of certain home appliances.

While there is certain ly both a replacement and remodeling market for some appliances

, including dishwashers , these products are also fixtures in virtually all new homes.

Table 3.9

. 1 presents the number of new single

- family and multi

- family housing units

started in the United States from 1998 to 20 10

. Over the 5

- year period from 2000

– 2005, single

family home starts increased 34.8 percent, to 1,716,000 units annually. However, between 2005

and 20 10 , single

- family home starts decreased 72.6 percent, to 471 ,000 units annually. Multi

family unit starts remained relatively stable during the period 1998

– 2005 at around 350,000 units annually. Between 2005 and 20 10 , multi

- fa mily units decreased 67.1 percent to 1 16 ,000 units annually

.

Table 3.9

. 1 New Privately Owned Single

- Family and Multi

- Family Housing Unit Starts in

the United States from 1998

– 20 10 (Thousands) 12

Year Single

Unit Multi

Unit

2010 471 116

2009 445 109

2008 622 284

2007 1046 309

2006 1465 336

2005 1716 353

2004 1611 345

2003 1499 349

2002 1359 346

2001 1273 329

2000 1231 338

1999 1302 339

1998 1271 346

3.9.2 Unit Shipments

AHAM’s 2005 Fact Book provides annual unit shipments for residential dishwashers

from 1995 to 2005

. Shipments for 2006 through 20 10 were obtained from the January 20113-12

Appliance Market Research Repor t ’s “U.S. Appliance Shipment Statistics January 2011 .” The

two sources c ontain consistent shipment values for the overlapping years 2000 through 2005.

Table 3.9

. 2 presents the annual shipments of dishwashers for the 1 4

- year period from 19 95 to

20 10

.

Shipments of residential dishwashers peaked in 2005 at around 7.4 million units before declining every year through 2009. The decline in shipments corresponds to the decline in new

multi

- family and single

- family housing starts over the same t ime period. Dishwasher shipments increased slightly in 2010, corresponding to the small increase in multi

- family and single

- family housing starts for that year.

Table 3.9

. 2 Industry Shipments of Residential Dishwashers (Domestic and Import) 13

, 14

Year Shipments (Thousands)

2010 5,708

2009 5

, 404

2008 5

, 995

2007 6

, 977

2006 7

, 252

2005 7

, 428

2004 7

, 106

2003 6

, 428

2002 6

, 207

2001 5

, 627

2000 5

, 827

1999 5

, 712

1998 5

, 144

1997 4

, 826

1996 4

, 606

1995 4

, 346

ENERGY STAR also provides shipment s data and market share for qualified residential

dishwashers

. Table 3.9

. 3 presents the breakdown of ENERGY STAR versus non

- E NERGY

STAR shipme nts for residential dishwashers from 2000 to 2009 from data provided on the

ENERGY STAR website.3-13

Table 3.9

. 3 ENERGY STAR Dishwasher Shipments and Market Share (Domestic and Import ) 15
Shipments

(Thousands)

Year %

ENERGY

STAR Total ENERGY

STAR

2009 a 68.0% 5

, 400 3

, 672

2008 67.2% 5

, 995 4

, 030

2007 b 77.4% 6

, 977 5

, 401

2006 92.3% 7

, 252 6

, 691

2005 82.0% 7

, 428 6

, 092

2004 78.2% 7

, 106 5

, 557

2003 56.9% 6

, 428 3

, 656

2002 36.4% 6

, 207 2

, 262

2001 19.9% 5

, 627 1

, 119

2000 c 10.9% 5

, 827 632 a) Current ENERGY STAR criteria (effective August 11, 2009) b) ENERGY STAR criteria (effective January 1, 2007): Standard

– EF ≥ 0.65, Compact

– EF ≥ 0.88 c) ENERGY STAR criteria: Standard

– EF ≥ 0.46, Compact

– EF ≥ 0.62

3.9.3 Value of Shipments

Table 3.9

. 4 provides the value of shipments for the manufacturers in the North American Industry Classification System ( NAICS ) category of major household appl iances (product class code 33522) from 1997 to 20 10 . The values are based on data from the U.S. Census Bureau’s Current Industrial Reports g ( CIR ) and Annual Survey of Manufacturers h ( ASM ). This NAICS category includes companies primarily engaged in manufacturing household appliances such as

cooki ng appliances, laundry equipment, refrigerators, upright and chest freezers, dishwashers, water heaters, and garbage disposal units. The U.S. Census Bureau reports all shipment values in nominal dollars, i.e. , 20 10 data are expressed in 20 10 dollars and 2 00 9 d ata are expressed in

200 9 dollar s . Using the Gross Domestic Product Implicit Price Deflator (GDPIPD) published by the U.S. Bureau of Economic Analysis

, i DOE converted each year’s value of shipments to 2010

dollars.

g Available online at www.census.gov/manufacturing/cir/index.html

h Available online at www.census.gov/manufacturing/asm/index.html

i Available online at www.bea.gov/national/nipaweb/SelectTable.asp3-14

Table 3.9

. 4 Annual Shipment Value of Major Household Appliance s 16

, 17

, 18

, 19

, 20

Annual Shipment Value ($ millions)

Year Nominal

Dollars 20 10

Dollars

2010 18,823.6 18,823.6

2009 18, 253.8 18, 427.7

2008 17,808.0 18,142.5

2007 19,575.0 20,378.5

2006 20,255.0 21,707.0

2005 20,730.0 22,939.6

2004 19,747.4 22,581.7

2003 18,721.7 22,016.2

2002 17,645.9 21,197.6

2001 17,295.5 21,113.1

2000 17,836.1 22,265.0

1999 17,479.6 22,292.6

1998 16,713.9 21,629.3

1997 15,487.1 20,268.3

Table 3.9

. 5 provides the annual shipment value for the NAICS product class for “O ther

H ousehold A ppliances ” (product class code 33522 8 ), which includes dishwashers, food waste disposal units, garbage dis posal units, water heaters, and trash compactors , from 1997 to 20 10 based upon data from the U.S. Census Bureau’s CIR and ASM

. Also included in Table 3.9

. 5 are dishw asher shipment values from 2006 to 2010

— the only years that dishwashers are specifically

broken out in the CIR

. Over these 4 years, dishwashers represented slightly less than half of the total annual shipments value for the Other H ousehold A ppliances prod uct category. The U.S. Census Bureau shipment values are expressed in nominal dollars. DOE used the GDPIPD to

convert each year’s value of shipments to 20 10 dollars

.3-15

Table 3.9

. 5 Annual Shipment Value of Other Major Household Appliance s 21

, 22

, 23

, 24

, 25

, 26

, 27

,

28

Annual Shipment Value ($ millions)

Other Ho me Appliances Dishwashers

Year Nominal

Dollars 2010

Dollars Nominal

Dollars 2010

Dollars

2010 4,553.1 4,553.1 1,690.4 1,690.4

2009 4,4 79.9 4, 522.6 1,709.5 1,725.8

2008 4,722.9 4,811.6 2,114.2 2,153.9

2007 4,581.7 4,769.8 2,189.0 2,278.9

2006 4,319.4 4,629.0 1,954.4 2,094.5

2005 4,263.5 4,717.9 N/A N/A

2004 4,042.9 4,623.2 N/A N/A

2003 3,428.1 4,031.4 N/A N/A

2002 3,422.7 4,111.6 N/A N/A

2001 3,579.7 4,369.8 N/A N/A

2000 3,540.7 4,419.9 N/A N/A

1999 3,362.3 4,288.1 N/A N/A

1998 3,255.1 4,212.4 N/A N/A

1997 3,232.1 4,229.9 N/A N/A

According to data presented in the AHAM 2003 Fact Book , many old appliances are still being used after consumers purchase new units of same product. Table 3.9

. 6 presents the various methods by which consumers dispose of their older dishwashers

.

Table 3.9

. 6 Disposition of Previous Dishwasher 29

Product Kept It Left with

Previous

Home Sold /

Gave Away Recycling

Facility Left at

Curb for Disposal Retailer

Took Away

Dishwashers 4 % 37 % 15 % 14 % 11 % 20 %

3.9.4 Imports and Exports

There is a large market for the import and export of home appliances. Each month AHAM publishes import and export data for certain home appliances, which includes year

- to

date annual summaries. Table 3.9

. 7 shows selected import/export data from AHAM’s Import/Export Trade Reports for December 200 8

– 20 0 9 as well as AHAM’s Final 2006 Major Appliance Trade Report (Imports & Exports)

. Over th e 5

- year period of 2005 through 2009

, imports and exports both rose as a share of total shipments. Overall, the United States imports more dishwashers than it exports.3-16

Table 3.9

. 7 Annual Dishwasher Imports/Exports 30

, 31

, 32

Year Imports (% of total shipments) Exports

(% of total shipments)

2009 611,743 (11.3%) 413,308

(7.7%)

2008 659,645 (11.0%) 432,332

(7.2%)

2007 639,866

(9.2%) 432,610

(6.2%)

2006 542,012

(7.5%) 409,817

(5.7%)

2005 527,983

(7.1%) 345,125

(4.6%)

3.10 HISTORICAL EFFICIENCIES

The average efficiency of new dishwashers has increased greatly since 1990

. Table

3.10

. 1 shows the shipment

- weighted average energy consumption per cycle. Over the period

from 1990 to 20 10 , the average energy consumption per cycle decreased by over 48 percent.3-17

Table 3.10

. 1 Annual Shipment

- Weighted Per

- Cycle Dishwasher Energy Consumption 33 , 34

Year Energy Consumption (kWh/cycle) %

Change

vs. 1990

2010 a 1.37

- 48.7%

2009 1.45

- 45.7%

2008 1.52

- 43.1%

2007 1.53

- 39.0%

2006 1.63

- 37.5%

2005 1.67

- 37.1%

2004 1.68

- 37.1%

2003 1.83

- 31.5%

2002 1.84

- 31.1%

2001 1.92

- 28.1%

2000 2 .00

- 25.1%

1999 1.98

- 25.8%

1998 1.97

- 26.2%

1997 2.02

- 24.3%

1996 2.06

- 22.8%

1995 2.07

- 22.5%

1994 b 2.14

- 19.9%

1993 2.56

- 4.1%

1992 2.66

- 0.4%

1991 2.67 0.0%

1990 2.67

- a) Current DOE energy conservation standards for annual energy use took effect on January 1,

2010. b) DOE energy conservation standards for EF took effect on May 14, 1994.

3.11 MARKET SATURATION

AHAM’s 2005 Fact Book and the January 2010 Appliance Market Research Report

present the mark et saturation for dishwashers. T he market saturation of dishwashers has more than tripled since 1970

. However, from 2001 through 2008 the market saturation only increased by 1.7 perce nt. For the 3 years from 2006 through 2008, the market saturation remained constant at 61 percent. Table 3.11

. 1 presents the percentage of U.S. households with dishwashers

.3-18

Table 3.11

. 1 Percentage of U.S. Households with Dishwashers 35

, 36

Y ea r % of U.S.

Households

2008 61 .0

2007 61 .0

2006 61 .0

2005 60

. 5

2004 6 0.0

2003 59

. 5

2002 59

. 5

2001 59

. 3

1990 53

. 9

1982 44

. 5

1970 18

. 9

3.12 PRODUCT RETAIL PRICE S

Tab le 3.12

. 1 presents the average reta il prices (in nominal dollars) for dishwashers and the consumer price index (CPI) for each year (1982

– 19 84 = 100). While prices for dishwashers rose

from 1980 to 200 2, they dropped dramatically from 2002 to 2005 resulting in a net decrease in average retail price between 1980 and 2005. The decrease in prices is even more significant

when factoring in the 137 percent increase in the CPI over the same time period.3-19

Tab le 3.12

. 1 Average Dishwasher Retail Prices 37

Average Retail Prices (Nominal $) Percent Change

1980 1994 2002 2005 1980

– 2005

Dishwashers 353 395 400 284

- 19.5%

Consumer Price Index a 82.4 148.2 179.9 195.3 137.0%

a) U.S. Department of Labor, Bureau of Labor Statistics, Consumer Price Index: U.S. C ity

A verage . 1982

– 19 84 = 100.

DOE conducted an in

- depth search of consumer retail prices for dishwashers by gathering consumer prices from three major appliance retailers: Sears, Home Depot, and AJMadison.com. The Sears and Home Depot websites were used for this search. DOE identified a total of 23 5

standard

- size models , which encompassed 28 different brand s. For models that were available in multiple colors, or at multiple retailers, DOE used the least expensive full price, not including

retail discounts. DOE used the California Energy Commission ( CEC ) j and ENERGY STAR k
product databases to match the rate d energy and water consumption data with each dishw asher

model.

Figure 3.12

. 1 and Figure 3.12

. 2 summarize the data collected by DOE. The figures show that retail price is loos ely related to efficiency, more so for energy use than for water consumption. The consumer retail prices for standard

- size dishwashers ranged from $ 239 to $ 2

, 36 9, with a (non

- shipment

- weighted) average of $ 883

. D ishwashers are available with annual

energy use ratings between 300 and 324 kWh/year at price

- points ranging from $250 to $2250

. However, the baseline retail price generally increases for dishw ashers as annual energy use

decreases below 300 kWh/year. The data comparing price with rated water consumption do not show such a clear trend. However, in general, the data show that retail price rises slightly for units with lower water use ratings.

j CEC appliance efficiency database available online at: www.energy.ca.gov/appl iances/database/

. k ENERGY STAR database available online at: www.energystar.gov/index.cfm?fuseaction=find_a_product.showProductGroup&pgw_code=DW3-20

Figure 3.12

. 1 Standard

- Size Residential Dishw asher Retail Price as a Function of Annual Energy Use

Figure 3.12

. 2 Standard

- Size Residential Dishw asher Retail Price as a Function of Water Consumption3-21

3.13 INDUSTRY COST STRUCT URE

DOE developed the household appliance industry cost structure from publicly available

information from the ASM and Economic Census , ( Table 3.13

. 1 and Table 3.13

. 3 ) and the U.S. Securities and Exchange Commission (SEC) 10

- K reports filed by publicly owned manufacturers (summarized in Table 3.13

. 5 ). Table 3.13

. 1 presents the major appliance manufacturing i ndustry (NAICS code 33522) employment levels and earnings from 1997 through 200 9

. The statistics illustrate a steady decline in the number of prod uction and non

- production workers in the industry since 2000.

DOE converted the payroll data to constant 2010 dollars using the GDPIPD published by the U.S. Bureau of Economic Analysis

. l Table 3.13

. 1 shows that as industry employment levels decline, the industry payroll in constant 2010 dollars also decreas es

. The percent decrease in total industry employees tracks closely with the percent decrease in payroll for all employees.

Table 3.13

. 1 Major Appliance Manufacturing Industry Employment and Earnings 38

Year Production

Workers All

Employees Payroll for

All Employees (2010 $ Mil)

2009 32,875 37,905 1,525.7

2008 39,163 44,717 1,822.1

2007 45,370 52,045 2,038.7

2006 49,360 56,174 2,298.0

2005 54,083 62,877 2,427.9

2004 57,660 68,213 2,701.5

2003 58,289 68,593 2,738.0

2002 59,234 70,013 2,867.8

2001 60,669 70,938 2,951.1

2000 64,417 75,055 3,163.0

1999 64,066 73,884 3,106.4

1998 62,822 73,113 3,036.7

1997 59,697 69,727 2,838.4

Table 3.13

. 2 presents the employments levels and payroll for the “ Other Major Home Appliances” portion of the major appliance industry. As shown in Table 3.9

. 5 , dishwashers represent slightly less than half of the total shipments value for the O ther M ajor H ome A ppliance industry. Statistics for both employment levels and payroll show a slight decrease from 1997 to

2 009 . The decrease is of a much smaller magnitude than for the major appliance industry

overall.

l A vailable online at www.bea.gov/national/nipaweb/SelectTable.asp3-22

Table 3.13

. 2 Other Major Home Appliance Industry Employment and Earnings 39

Year Production

Workers All

Employees Payroll for

All Employees (2010 $ Mil)

2009 7,651 9,516 408.7

2008 9,103 11,113 471.7

2007 9,792 11,516 490.5

2006 10,281 11,974 520.7

2005 10,179 12,360 535.7

2004 10,304 12,672 549.2

2003 10,519 12,819 549. 9

2002 10,118 12,671 579. 3

2001 10,392 12,770 576. 6

2000 11,775 14,088 592. 5

1999 11,081 13,166 577. 1

1998 11,195 13,215 544.8

1997 10,881 12,848 535. 8

Table 3.13

. 3 presents the costs of materials and industry payroll as a percentage of value of shipments from 1997 to 2009 for the major appliance industry

. The cost of materials as a percentage of value of shipments has slowly risen over the 1 3

- year period, with small

fluctuations . DOE notes that fluctuations in raw material costs are common from year to year. The cost of payroll for both production and non

- production workers as a percentage of value of ship ments has declined since 2000.

Table 3.13

. 3 Major Appliance Manufacturing Industry Materials and Wages Cost 40

Cost as a Percentage of Value of Shipments (%)

Year Materials Payroll for

Production

Workers Payroll for

All Other Employees

2009 55.0% 7.8% 2.4%

2008 59.4% 7.8% 2.2%

2007 58.4% 8.0% 2.0%

2006 58.7% 8.5% 2.1%

2005 57.4% 8.3% 2.3%

2004 58.3% 9.3% 2.7%

2003 56.8% 9.5% 2.9%

2002 57.0% 10.2% 3.3%

2001 58.5% 10.7% 3.3%

2000 57.3% 10.8% 3.4%

1999 55.7% 10.7% 3.2%

1998 55.6% 10.8% 3.2%

1997 53.4% 10.9% 3.1%3-23

Table 3.13

. 4 shows the cost of materials and industry payroll as a percentage of value of shipments for the other major appliance industry from 1997 to 200 9

. Material prices as a percentage of value of s hipments have remained relatively constant o ver the 13

- year period, with fluctuations from year

- to

- year

. The cost of p ayroll for production and other employees has remained relatively constant over the 1 3

- year period, with fluctuations from year

- to

- year

. DOE notes that, overall, wages and cost of materials combined represent a smaller percentage of the total shipments value for the other major appliance industry than for the major appliance industry

as a whole.

Table 3.13

. 4 Other Major Appliance Industry Materials and Wages Cost 41

Cost as a Percentage of Value of Shipments (%)

Year Materials Payroll for

Production

Workers Payroll for

All Other Employees

2009 46.3% 7.2% 2.9%

2008 50.2% 6.9% 2.9%

2007 53.1% 7.9% 2.4%

2006 53.8% a 8.7% 2.5%

2005 52.0% 8.4% 3.0%

2004 51.0% 8.7% 3.1%

2003 52.7% 10.0% 3.7%

2002 45.9% 10.1% 4.0%

2001 49.5% 9.3% 3.9%

2000 50.4% 9.8% 3.6%

1999 51.6% 10.2% 3.3%

1998 48.3% 10.0% 3.0%

1997 44.7% 9.8% 2.9%

a) Cost of Materials data not available for 2006; the average value from 2005 and 2007 was used as an estimate.

Table 3.13

. 5 through Table 3.13

. 7 present the industry financial parameters derived from publicly available sources of financial data including SEC 10

- K reports for U.S.

- based home appliance manufacturers whose range of produ cts includes residential dishwashers. DOE averaged the financial data from 2003

– 2010 for each manufacturer and weighted this by their respective market share to obtain an industry average. Each financial statement entry is presented as a percentage of tot al revenues.3-24

Table 3.13

. 5 Industry Financials from Income Statement , Average 200 3

– 20 10

Income Statement Entry Percent of

Revenues

Cost of sales 80.6% Selling, general and administrative 13.3%

Research and development 2.3% Depreciation * 3.1 % Earnings before interest and taxes 5.7% *Depreciation appears on both the income statement and cash flow statement.

Table 3.13

. 6 Industry Financials from Cash Flow Statement, Average 2003

– 2010

Cash Flow Statement Entry Percent of

Revenues Capital expenditure 3.2%

Table 3.13

. 7 Industry Financials from Balance Sheet, Average 2003

– 2010

Financial Statement Entry Percent of

Revenues Net plant, property and equipment 16.7% Working capital 7.0%

A detailed financial analysis is presented in the manufacturer impact analysis ( c hapter 1 2

of th e final rule TSD). This analysis identifies key financial inputs including cost of capital, working capital, depreciation, capital expenditures, etc.

3.14 INVENTORY LEVELS AND CAPACITY UTILIZATION RATES

Table 3.14

. 1 and Table 3.14

. 2 show the year

- end inventory for the major appliance manufacturing and other major app liance manufacturing industries, according to the ASM

. Both in dollars and as a percentage of value of shipments, the end

- of

- year inventory for the major appliance industry steadily declined between 1997 and 200 5

. Inventor ies increased as a percentage of the total value of shipments beginning in 200 6

, corresponding to the deterioration

of the U.S. economy during that period

. Other major appliance inventories do not show these

same trends. The value of the end

- of

- year inventories remain ed relatively stead y over the 13

- year period, as did the inventory as a percentage of total shipment values, with fluctuations from

year

- to

- year.3-25

Table 3.14

. 1 Major Appliance Manufacturing Industry Inventory Levels 42

Year End

- of

Year Inventory (2010 $ Mil) EOY Inventory

as % of Shipments

Value

2009 1,338.6 7.3%

2008 1,412.5 7.8%

2007 1,536.9 7.5%

2006 1,351.0 6.2%

2005 1,388.0 6.1%

2004 1,413.4 6.3%

2003 1,395.8 6.3%

2002 1,500.6 7.1%

2001 1,663.7 7.9%

2000 1,890.7 8.5%

1999 1,901.3 8.5%

1998 1,939.1 9.0%

1997 1,866.5 9.2%

Table 3.14

. 2 Other Major Appliance Manufacturing Industry Inventory Levels 43

Year End

- of

- Year Inventory (2010 $ Mil) EOY Inventory as

% of Shipments

Value

2009 270.6 6.0%

2008 338.7 7.0%

2007 309.9 6.5%

2006 336.6 7.3%

2005 324.1 6.9%

2004 340.7 7.4%

2003 326.3 8.1%

2002 281.1 6.8%

2001 342.4 7.8%

2000 369.5 8.4%

1999 327.5 7.6%

1998 298.2 7.1%

1997 302.7 7.2%

DOE obtained full production capacity utilization rates from the U.S. Census Bureau ’s Survey of Plant Capacity from 1997

– 200 6

. After 2006, the Census Bureau discontinued this survey, and began a new Quarterly Survey of Plant Capacity Utilization . However, this survey does not break down the utilization data beyond the “all household appliances” industry. Table

3.14

. 3 presents util ization rates for various sectors of the household appliance industry.3-26

Full production capacity is defined as the maximum level of production an establishment could attain under normal operating conditions. In the Survey of Plant Capacity reports, the full production utilization rate is a ratio of the actual level of operations to the full production level. The full production capacity utilization rate for all household appliances show s fairly steady

utilization between 70 and 7 8 percent from 1997 thr ough 200 7 , with a significant decrease to less than 60 percent from 2007 through 2009. However, in 2010 the utilization rate rebound ed slightly from its low in 2009. Data for major appliance and “ other major household appliance ”

manufacturers tracks closely with the overall household appliance data from 1997 through 2006.

Table 3.14

. 3 Full Production Capacity Utilization Rates 44

, 45

Year Plant Capacity Utilization Rates (%)

All

Household Appliances Major

Appliances a Other

Major

Home Appliances a

2010 67% N/A N/A

2009 58% N/A N/A

2008 59% N/A N/A

2007 76% N/A N/A

2006 77 % 79% 83%

2005 74 % 76% 78%

2004 76 % 77% 77%

2003 78 % 76% 81%

2002 72 % 74% 74%

2001 70 % 71% 71%

2000 70 % 71% 71%

1999 75 % 77% 83%

1998 73 % 76% 87%

1997 73 % 74% 84%

a) Data unavailable after 2006.

3.15 TECHNOLOGY ASSESSMEN T

This section provides a technology assessment for residential dishwashers. Contained in this technology assessment are details about product characteristics and operation (section

3.15.1 ), an examination of possible technological improvements (section 3.15.2 )

, and a characterization of the product efficiency levels currently commercially available (section

3.15.3 ).

3.15.1 Dishwasher Operations and Components

Residential dishwa shers are a product designed to clean dishes, utensils, and cookware by using a solution of detergent and heated water. Dishwashers spray this solution from rotating spray arms onto the dishes in order to clean and sterilize them. Dishwashers use electri city to3-27

power an electric motor for the pump system that circulates the wash solution, a heating element which heats the wash solution and assists in drying the dishes, and an optional drain pump. In addition, dishwasher controls consume some electricity and some dishwashers contain a drying fan which circulates air through the dishwasher to aid dish drying. Although al most all dishwashers are capable of heating water with their internal heating element, dishwashers in the

United States are typically conn ected to the hot water line to supply hot water. Water is automatically fed to the dishwasher through an electrically

- operated water valve connected to the hot water pipe. The dishes, utensils, and cookware are washed, rinsed and dried within a tub that

is inside the dishwasher cabinet.

Dishwashers are traditionally front

- loading appliances. The door on the front of the cabinet cantilevers down, and the washer racks slide out on railings for loading and unloading.

When the dishwasher is loaded and the washer racks are slid into the dishwasher cabinet, the cabinet door is closed, sealing the tub, and a door switch indicates that the door latch has sealed the cabinet door. The dishwasher controls, which may be electromechanical or electronic, can

then be gin the wash cycle.

The wash cycle begins when the water fill valve fills the dishwasher tub until the control timer indicates a complete fill, or the dishwasher float switch indicates that the tub is full

, or a water meter indicates a sufficient amount o f water has entered the tub. The main pump, which provides pressurized fluid to the dishwasher spray arms, is attached to the sump of the tub, where water accumulates. The pump, which uses a rotating impeller to pressurize the fluid and deliver

it to the spray arms, is connected directly to the electric motor, or connected by a belt or other form of transmission. The heating element can be part of the sump or installed above it. The heating element ensures the water is heated to an adequate temperature for cleaning. The detergent is released from an electrically controlled detergent container which is filled with detergent prior to initiating the dishwashing cycle.

Dishwashers can be further segregated, depending on whether they feature one or two

pump s. On a one

- pump model

, the main pump not only pressurizes the wash and rinse system, but it can also be used to drain the wash fluid, either by reversing the pump direction (forcing the fluid out the drain), or by using a diverting valve located on the p ump output line. Dishwashers with two pumps use one pump optimized for cleaning and rinsing procedures and a second pump optimized for draining. After each drain cycle (until the cleaning cycle ends), the tub is refilled with water for rinse or wash oper ations. Dishwashers may drain and refill the tub multiple times during the dishwashing cycle as the washing and rinsing water becomes soiled. In some dishwashers this process is controlled by a timer, while other dishwashers use sensors and

electronic co ntrols to determine when to change the water, the amount of water for each fill, water temperatures in each cycle, and other variables.

The heating element is activated to heat the dishwasher cabinet and speed up drying once the dishwasher completes the r inse and drain cycles. Dishwashers with an additional drying fan and air heater utilize these devices during the drying phase of the wash cycle.3-28

Some dishwashers use separate drawers for each washing rack, instead of one large tub

with two or more racks running on extensible rails. These multi

- drawer dishwashers are essentially two small dishwashers stacked on top of each other. This two

- drawer system allows users to run the dishwasher with smaller loads without wasting the water or energy a full

- size

d ishwasher would use on a half

- empty load

.

3.15.2 Dishwasher Technology Options

For dishwashers , DOE will consider technologies identified in the following three

sources: (1) DOE’s ANOPR initiating a standards rulemaking for residential dishwashers, dehumidifiers, cooking products, and commercial clothes washers published on November 1 5

, 2007 (72 FR 64432 ); (2) information provided by trade publications; and (3) design data

identified in m anufacturer product offerings.

The technology options for dishwashers are listed in Table 3.15

. 1

. They are changes that can be incorporated into the design of a dishwasher to improve its efficiency

.

Table 3.15

. 1 Technology Options for Residential Dishwashers

1. Condenser drying

2. Control s trategies

3

. Fan /jet drying

4

. Flow

- through heating

5

. Improved fill control

6 . Improved food filter

7 . Improved motor efficiency

8 . Improved spray

- arm geometry

9 . Increased insulation

10. Low

- standby

- loss electronic controls

11

. Microprocessor controls and fuzzy logic, including adaptive or soil

- sensing controls

12

. Modified sump geometry, with and without dual pumps

13 . Reduced inlet

- water temperature

1 4 . Supercritical carbon dioxide washing

1 5 . Ultrasonic washing

16

. Variable washing pressures and flow rates

Condenser drying

This technology reduces the amount of energy required to dry the dishes at the end of the wash cycle. Instead of using an exposed electric heating element to dry the dishes, hot rinse water is used to heat the dishes to a high temperature. Subsequently, room air is admitted into the dishwasher. Simple convection then pulls cooler, less moist air into the dishwasher from the bottom of the cabinet and discharges warm, moist air out of the top of the cabinet. Some designs

do not allow outside air into the dishwasher and pull cool air over the exterior cabinet surface instead. As the warm, moist air inside the dishwasher encounters the cavity walls (via natural3-29

convection)

, the water condenses on the wall surface and runs into the sump. Most European

insta llations connect the dishwasher to the cold water line. A reservoir of cold water can thus be maintained on the outside of the stainless tub, providing a chilled surface on which the moisture can condense. U.S. condensing systems are less effective becau se the condensing surface is not

as cool.

Control s trategies

Effective dishwashing requires water, heat, mechanical action (spraying of water), time, and detergent. Manufacturers may adjust the controls of a dishwasher to limit the amount of

water used , or the set

- point temperature of the wash or rinse water. This improves efficiency by decreasing the amount of energy associated with water heating. To help compensate for the negative impact on cleaning performance associated with decreasing water use and water temperature, manufacturers will typically increase the cycle time. This allows more time for the smaller volume of water to be circulated within the cabinet, helping to maintain wash performance.

Fan /jet drying

To reduce drying times, some dis hwasher designs use a fan to circulate air and to accelerate the drying process outlined in the condenser drying section above. Fans may be

installed in the dishwasher door or in the cabinet itself, with the condensing water being diverted

back into the s ump. Convection fan systems are found on some of the highe r efficiency

dishwashers currently available on the U.S. market.

Flow

- through heating

As discussed in section 3.15.1 , dishwashers use either an exposed tubular or a flow

through supplemental water heating element to bring water inside the dishwasher up to operating temperature. Water is heated before being pumped and distributed to the spray arms. Typically, dishwashers with exposed tubular heating elements require more standing water than

dishwashers with flow

- through heaters. Flow

- through heaters consist of a metallic flow tube

around which an electrica l tubular resistance heater is wrapped. The flow

- through heater usually connects the sump to the main pump and hence forms an integral part of the water circuit. The volume of water required to fill a flow

- through element is typically much lower than the volume required to at least partially submerge a tubular supplemental heating element. The potential water and energy savings depend upon the configuration of the sump and type of supplemental water heating element.

Improved fill control

Modifying the fill control to admit a lower volume of water can reduce hot water consumption and energy use. In models that use electro

- mechanical controls, this could be accomplished by reducing the safety factor employed by manufacturers to ensure proper fill

volumes . Safety factors, which result in overfill for some consumers, are applied to the volume3-30

of the sump region and also to the timer

- activated water fill to ensure enough water for proper pump action and cleaning. The use of more accurate electronic timers would maintain a tighter tolerance on the fill time period.

Dishwashers with electro

- mechanical controls also employ an overfill factor to account for varying water pressures. Water flow rates through valves vary with water pressure, so the

use of mechanical timer controls could cause a variation in the quantity of hot water delivered. Therefore, an additional overfill factor of 10 or 15 percent is traditionally used to compensate for the range of water pressures existing in the United States The use of pressure

- activated water

volume sensors could be used to control water fill rather than a mechanical timer to reduce

overfills.

Dishwashers may alternatively use a float switch mounted in the sump to terminate the filling process. The float switch is an electro

- mechanical switch activated by the rising water level in the sump. Once the sump has been filled to the app ropriate level, the float triggers the switch, terminating the fill. Because the float switch directly measures the water level, it can enable a high degree of fill control. However, simple float switches can only measure one fill level, which may be ina dequate for washers with very high efficiency targets.

The most sophisticated water fill control option is to incorporate a water meter into the

dishwasher. Such a device allows the controller to measure exactly how much water has been

added and allows the washer to tailor its water input precisely to the needs of each individual wash or rinse cycle. By metering the water precisely, this approach gives the dishwasher controller greater flexibility than a timed fill or float switch. However, unlike a ti med fill or a float switch, a water meter approach requires an electronic dishwasher controller that can make use of the pulses generated by the water meter.

Improved f

ood f ilter

Improved food filters help prevent the re

- deposition of food particles, po ssibly leading to one less fill for rinsing. Dishwashers utilizing fine filters have less food re

- deposited on dishes,

because the food is filtered out before being re

- circulated by the pump through the spray arms. Another benefit is that the water suppl y lines, nozzles, etc. can have small cross

- sections without

the risk of clogging due to entrained food particles. Thus, a fine food filter can enable a

manufacturer to reduce the volume of the water nee ded to fill all parts of the water system.

Typical filter designs have a self

- cleaning feature that backwash es the filter automatically and therefore minimizes manual filter cleaning. Although less water is required overall for dishware rinsing, the washing of the filter requires water use. The task can be changed to an intermittent event via the inclusion of a pressure transducer, which can sense how clogged the filter is and thus signal a rinse requirement to an electronic controller. The filter is cleaned whenever the need arises, allowing the design er to implement lower

- volume sump designs. Another implementation approach could monitor the pump motor directly to detect excessive slip, resistance, or other parameter to infer a clogged filter condition.3-31

Improved motor efficiency

An electric motor runs the main water pump and, if separate, the drain pump as well. Dishwashers have typically used split

- phase or shaded

- pole motors because of their low torque requirement and constant starting current condition. A capacitor

- type motor, such as a

perman ent split capacitor (PSC) motor, is more efficient than a split

- phase or shaded

- pole motor. It uses a capacitor in both the starting and running modes. The capacitor

- type motor increases the power factor, and, therefore, reduces heating losses in the sta tor. An electric motor efficiency of 65 percent should be possible using a capacitor

- type motor.

A 30

- percent improvement in motor efficiency produces approximately a 2.5

- percent overall reduction in dishwasher energy consumption. Dishwashers with per manent magnet motors could reduce the electrical consumption of the pump motor by a further 10

– 20 percent

from the levels attainable with PSC motors.

Improved spray

- arm geometry

Spray arms, which are typically located at the center and the bottom of a dishwasher cavity, are designed to rotate and spray pressurized water on the dishwasher contents. If the

spray arms are designed to more effectively remove food particles, the dishwasher will use less hot water and energy.

Increased insulation

Some d ishwashers feature some insulation to reduce noise levels . Generally, these dishwashers use bitumen attached to the wash tub to dampen noised caused by vibrations in the tub during operation. However, the added thermal mass of the bitumen insulation typi cally results in higher energy consumption. Other dishwashers use a cotton liner to decrease heat

losses from the tub. The cotton insulates the wash tub with a lower thermal mass than bitumen.

The marginal benefit for this type of additional insulation is very small.

Low

- standby

- loss electronic controls

Electronic controls may consume power even when the dishwasher is not performing its intended function. Depending on the implementation of the controller, standby power is required

to enable the elect ronic controls to detect user input without the user first having to turn on a mechanical power switch or to enable displays, illuminate switches, etc. Reducing the standby power consumption of electronic controls will reduce the annual energy consumption of the dishwasher, but will not impact the energy consumption of the dishwasher during operation.

Low

- standby

- loss electronic controls can be implemented in a wide variety of ways.

Microprocessor controls and fuzzy logic, including adaptive or soil

- sens ing controls

Microprocessor controls and fuzzy logic

, including adaptive or soil

- sensing controls

, are able to reduce the energy and water consumption of a dishwasher by allowing the machine to3-32

adapt to variable conditions inside the unit. Sensors locate d inside the dishwasher provide a stream of information, including turbidity, conductivity, temperature, and spray arm rotation, to the fuzzy logic controller which, in turn, controls the operation of the dishwasher by adjust ing

the amount of water used an d/or the water temperature

, based on inferred load and/or soil level

. This is somewhat analogous to manually selecting light

- , normal

- or heavy

- duty wash selection.

For example, some dishwasher designs have sensors that m easure the amount of food soil

in the water and algorithms that adjust water temperature , fill level s, and cycle time accordingly. This design feature may also track the amount of time between loads so the controller can adjust

for dried

- on food

, as well as taking into account the numb er of times the door has been opened to

determine load size

. According to Honeywell, a key developer and supplier of soil

- sensing packages, such a system can reduce energy consumption by 35 percent and water consumption by 45 percent. 46 Most manufacturers offer dishwashers using soil

- sensing controls.

In 2003, the DOE test procedure was updated to more accurately measure energy efficiency for machines equipped with soil

- sensing controls

. For these machines, water and electrical energy consumption are mea sured under varying soil load conditions, and the results

are averaged via a weighted formula that represents typical usage patterns.

Modified sump geometry, with and without dual pumps

The amount of water used for each cycle can be reduced by a change i n the geometry of the sump and its integration with the main pump and a drain pump (if any ). During the wash part of the cycle, approximately half of the water at any given time in the dishwasher is in the sump

to ensure an air

- free water supply to the pump. Current sump designs attempt to minimize water use while maintaining an adequate water supply to the pump. This technology option would optimize the s ump to minimize the total amount of water needed per fill. Another factor in sump design is how quickly water can flow back to the sump after being sprayed on the dishes.

Many baseline dishwashers use one pump to deliver pressurized water , with detergent in

solution

, to the spray arms, and to drain the wash solution when the wash cycle is complete. This pump is powered by a single electric motor. By using two pumps and two electric motors,

with one set optimized for washing and one set optimized for dra ining, the overall energy consumption due to water pumping may be decreased.

Reduced inlet

- water temperature

This option uses cold temperature water for some of the rinse cycles. Dishwashers with adequate heating elements could tap only to the cold water supply line, allowing the dishwasher’s heating element to heat the water as required. For reduced

- temperature rinse cycles, the water would be heated to a lower temperature than the temperature of water typically

available from the hot water supply line (120 °F) , reducing energy consumption . The dishwasher’s internal water heater may also be more efficient than the household water heater.

For an example of a dishwasher incorporating this design option

, ASKO manufactures a

dishwash er capable of attaching directly to a cold water line. 47 However, ASKO notes that a3-33

dishwasher connected to the cold water line requires more time to complete the washing cycle,

because the dishwasher requires additional time to internally heat the water t o operating

temperatures

.

Alternatively, a dishwasher could tap both the hot and cold water lines

, and mix hot and cold water in order to reduce inlet water temperature s

. Again , because U.S. dishwashers are conventionally connected to a hot water line only, this option would necessitate plumbing in a cold water line to the dishwasher in addition to the currently

- used hot water line.

Another means to lower rinse water temperature is to lower the hot water temperature setting on the household water heater and use the dishwasher’s heating element to raise the water to the needed temperature. But lowering the household water heater temperature below 120 °F may not satisfy other household hot water requirements

.

Supercritical carbon dioxide washing

At an Electrolux

- sponsored design competition, students from the University of New South Wales designed a dishwasher with a cleaning process based upon supercritical carbon

dioxide instead of the c onventional detergent and water solution

. 48 The supercritical carbon

dioxide within the dishwasher behaves simultaneously as a liquid and a gas, completely filling the washing tub and covering the dishes, like a gas, but dissolving grease like a liquid. T he supercritical carbon dioxide is used in a closed

- loop process

. A fter the wash cycle,

contamination is removed from the carbon dioxide

, which is stored for the next wash cycle.

Ultrasonic washing

Ultrasonic washing uses high frequency sound generators to create cavitation bubbles

within the wash water, in which the dishware is completely submerged. These bubbles implode upon contact with a surface, effecting a mechanical scrubbing action that removes soil from the

dishware . This cleaning action is no t dependent on water temperature, water flow rate, or detergents, making the process highly energy efficient, because a standing pool of room temperature water may be used. However, standing ultrasonic waves within the washing cavity

and the force of cavi tation implosion can damage fragile dishware. Also, consumers may not perceive ultrasonic dishwashers as properly sterilizing dishes at low temperatures , resulting in a perceived decrease in consumer utility, even though not all current dishwashers operat e at high enough temperatures to effectively sterilize their contents.

Sharp introduced an ultrasonic and ionic dishwasher for the Japanese market in September 2002 , which utilizes a different ultrasonic technique for soil removal

. 49 The

dishwasher tank i s partially filled with water

, and a superfine mist is created using an ultrasonic generating element to remove food stains from dishes. Hard water ion washing is then performed using table salt. A prepared salt

- water mixture is put through an exchange system to make hard water containing an abundance of calcium ions (Ca2+) and magnesium ions (Mg2+). This water washes the dishes using a salting

- in effect to remove protein

- based stains, which

would otherwise become hardened and difficult to remove when u sing conventional heated tap3-34

water. The ion exchange system then removes calcium and magnesium ions from the tap water to create soft water for rinsing. The combination of the ultrasonic waves and the salt

- water mixture is designed to wash without the n eed for dishwasher detergent. Unlike the technology described above, Sharp’s ultrasonic dishwasher does not rely on immersing the dishes in a n ultrasonically excited fluid.

Variable washing pressure and flow rates

Variable washing pressure and flow rate s are being employed in some dishwasher models to reduce dishwashing cycle times or to accommodate the various levels of soiling . For example, the user can choose an option to provide a 30

- percent increase in washing pressure and, thus, more rapidly (and powerfully) clean dishes

. T he user interface usually presents this option as, for example, a “ pots and pans ” wash setting versus a “ normal ” setting. Higher energy consumption from the dishwasher pump is required to achieve the increase in washing pressur e.

Conversely, reduced washing pressure requires less energy from the dishwasher pump to run the cleaning cycles, reducing the energy consumption of the dishwasher as long as the cycle time is not increased. Such a strategy may be employed for rinse cyc les, during which clean water is used to remove detergent from the dishes. Because the rinse cycle does not need high washing pressure to remove food material from soiled dishes, a reduced water pressure is feasible without degrading the overall cleaning performance of the dishwasher.

Some dishwashers alternate the delivery of water to the top

- rack spray arm and the

bottom

- rack spray arm. This diversion is accomplished by using a valve or other fluid control mechanism to route the water to one spray arm at a time. Once the active spray arm has completed its cycle, the water may be circulated through the other spray arm to complete a similar cycle. This reduces the amount of water required by the dishwasher, because the dishwasher only heats and circula tes enough water for one spray arm. By reducing the amount of water required, and therefore the amount of water heating required, alternating water delivery to the top and bottom spray arms reduces the energy consumption of the dishwasher.

In order to implement this feature, the dishwasher must be capable of adequately filtering

the wash water. Because a smaller quantity of water is used to remove the same quantity of dish soiling, the water will contain a higher concentration of soiling. If the dish washer filtering system does not adequately filter the water, re

- deposition of food soiling could increase as the

soiled water is circulated.

In addition to reducing the energy consumption of dishwashers washing full loads, this technology option also let s manufacturers offer dishwashers with efficient “half

- load” wash cycles in which water is only routed to one spray arm , which allow consumers to run the

dishwasher when it is half

- full without wasting the water and energy necessary to wash a full

load.3-35

3.15.3 Energy Efficiency

In preparation for the screening and engineering analyses, DOE gathered data on the energy efficiency of dishwashers currently available in the marketplace. This data is taken from databases maintained by a variety of regulatory agencies . While this section is not intended to provide a complete characterization of the energy efficiency of all dishwashers currently available and in use, it does provide a rough representation of the range of available energy

efficiencies. The CEC publishe s a list of “certified” residential dishwashers

. Fi gure 3.15

. 1 displays the distribution of standard dishwashers in the CEC database , as of September 12, 2011,

as a function of estimated annual energy use , rounded down to 10 kWh per year intervals

.

Fi gure 3.15

. 1 Standard Dishwashers in the CEC Directory 503-36

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.

22 U.S. Census Bureau. 200 3 . “Table 2

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.

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30 AHAM

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32 AHAM. 20 06

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33 AHAM Fact Book . 2005.

34 AHAM, DO E Docket No. EERE

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.

35 Ibid.

36 “ U.S. Appliance Industry: Market Share, Life Expectancy & Replacement Market, and

Saturation Levels ”. Appliance Magazine Market Research Report

, January 2 010

.3-39

37 AHAM Fact Book . 2005.

38 U.S. Census Bureau. 1997

– 2009 . Statistics.

39 Ibid

.

40 Ibid.

41 Ibid.

42 Ibid.

43 Ibid.

44 U.S. Census Bureau, Survey of Plant Capacity

, 1997 to 2006

.

45 U.S. Census Bureau, Quarterly Survey of Plant Capacity Utilization , 2007 to 2010.

46 “An Intelligent Wash Process Sensor.” Scientific Honeyweller , Sensors Issue, 1996.

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48 Appliance Magazine , November 2005.

49 Appliance Magazine , October 2002.

50 California Energy Commission (CEC) Appliance efficiency database. Available online

at: www.energy.ca.gov/appliances/appliance/excel_based_files/ (Accessed September 12, 2011)