Drainage guide for the Commercial kitchen

Transcription

1 Drainage guide for the Commercial kitchen

2 Floor drainage Floor drainage functionality

3 2 ACO I Drainage guide for the Commercial kitchen

4 3 Contents 1. Introduction 2. Drainage types 3. Kitchen areas 4. Product portfolio 5. Installation examples 6. Cleaning and Maintenance 7. Material properties 8. Kitchen drawing examples

5 4 ACO I Drainage guide for the Commercial kitchen

6 5 1. Introduction 1. Introduction 1.1 The ACO group 1.2 The commercial kitchen: a hazardous environment 1.3 Hygiene, Health & Safety 1.4. Flexible product portfolio

7 6 ACO I Drainage guide for the Commercial kitchen 1.1 The ACO group With over 60 years experience in the design and manufacture of drainage components ACO have developed a unique global competence that has resulted in development of innovative and award winning products. As a recognised leader in many of our markets, our success is attributable to anticipating and understanding our customer needs: whether a large international producer or independent local operator, our resources extend to provide the levels of service and product excellence that are only possible from global research, development and production facilities that are implemented with local considerations in mind. ACO focus on hygiene ACO is one of the world s leading drainage specialists. We are familiar with HACCP and the prerequisites, including suitable drainage, which underpins it. We are thus committed to implement the requirements of the food industry into our product s design and development to meet the sector s needs on a risk reduction basis. Furthermore we are active in cooperation with major European institutions such as the EHEDG (European Hygienic Engineering & Design Group) or FCSI (Fooodservice Consultants Society International) who have expertise in hygienic design and commercial kitchen operations.

8 7 1. Introduction 1.2 The commercial kitchen: a hazardous environment All commercial kitchens can be characterised as a hazardous working environment they are extremely busy with the potential for wet and greasy floors due to the abundance of liquids in both the cooking and cleaning processes, and of course, liquids are often very hot! In combination, these factors may affect Food Safety and Health & Safety aspects of the kitchen. There are three principle areas in the commercial kitchen: storage and preparation, production, washing and disposal area. Each area represents different processes in the Commercial kitchen environment and therefore place different demands on floor drainage. Nevertheless there are some aspects which are common for all three. All areas have high demands on durability, long-life time, hygienic parameters and proper function of all drainage elements.

9 8 ACO I Drainage guide for the Commercial kitchen Storage and preparation area Storage areas represent all rooms where the food is stored such as deep freeze rooms, cold rooms, and storage rooms. Food storage areas will require occasional clean down as part of either a planned cleaning programme or in case of spillage. The preparation of food involves washing, paring or peeling, cutting, trimming or shaping. All these operations produce food debris, many use water either in automated machinery or manually in a sink. Production area The busy heart of the kitchen, where potentially most slips & falls can occur, requires the strategic positioning of floor drainage to aid in the removal of water that is being used in, or discharged from specialist cooking equipment such as Bratt Pans, Boiling Pans and Combination Ovens. Washing and disposal area Ware washing operations involve the removal of residual food, scraping, pre-soaking, rinsing and washing stages. Care must be taken to reduce the build up of fats oils and grease (FOG) in drainage plumbing and simply wiping off food residues can have a dramatic impact on the overall system. However every kitchen should have a proper FOG management strategy, ideally using EN certified Grease Separators.

10 9 1. Introduction 1.3 Hygiene, Health & Safety HACCP Efficient drainage assists in managing risk: operationally, it helps prevent accidents; hygienically, it is required by European Law - EC 852, and is embodied within the HACCP (Hazard Analysis and Critical Control Point) framework through the Prerequisite Programme (PRP). Illustrating adequate drainage design together with appropriate cleaning and maintenance procedures within the PRP is the prime objective of this guide. This process should also form part of the Design Risk Analysis for any building design. To incorporate these requirements ACO focus on three principle attributes in product conception and design: Hygienic design features Safety features Durability and functionality features Hygiene design features Easy clean design Appropriate materials (corrosion resistant in aggressive environments) Accessibility for cleaning Minimisation of bacteria traps Simple food debris collection and removal Design with maintenance in mind Protection against odour and backflow

11 10 ACO I Drainage guide for the Commercial kitchen Safety features: Slip resistant surfaces Efficient surface water removal Products specific to kitchen equipment type Ergonomic convenience enabling regular maintenance Durability and functionality features: Self draining gradients Optimal surface area to flow rate where high interception is required Accessibility to ongoing drainline Fully pickle passivated to enhance corrosion resistance Tested and certified to EN 1253 (gullies) and EN 1433 (channels) Fat and grease removal to EN 825

12 11 1. Introduction 1.4. Flexible product portfolio At ACO we go the extra mile to make sure your needs are accommodated. Whether your project is new-build or refurbishment our design advice and product range meet all your drainage needs internally and externally. Whether you are the client, the designer or contractor it s likely you will value two key attributes: Flexibility Economy These are often conflicting requirements; however we believe our sophisticated production facilities and investment in our skilled design team allow us to deliver on both measures. Stainless steel products can be segregated into three categories: Standard We hope to have a product that meets your application need precisely. Many of our products are modular in that they can be part of a larger system such detail in our product range assists the designer and contractor who no longer need wait for a special branch channel or corner unit. The product is defined in our catalogues with a part number. Generally it is held in stock and available for immediate delivery. Products are designed and tested in accordance with relevant national standards. Modified We can tailor many of our standard stainless steel products to your exact requirements with minimum impact on cost and delivery time. The product allows variation to a number of dimensions, dimension parameters are given at Examples include drainage channels that need to fit precisely in a given space, or are required to intercept unusual quantities of liquid. Bespoke ACO s competence in drainage is world renowned, generally market leading companies have little flexibility in their offer. ACO has chosen a different path with key competence centres and experts at your disposal to offer advice and design on your special drainage product requirements.

13 12 ACO I Drainage guide for the Commercial kitchen

14 13 2. Drainage types 2.1 Floor drainage 2. Drainage types 2.2 Drainage management

15 14 ACO I Drainage guide for the Commercial kitchen 2.1. Floor drainage Functionality Floors must be designed so that any liquids present on the floor are quickly and safely removed. This can be achieved with a floor gradient to the drainage point in the order of 1 1.5%. Floor drain capacity must be adequate for the intended application. Overall drain capacity can be affected by combination of factors including hydraulic head, outlet size, grating design, filter basket or sieve design and any foul air trap provision. Generally specify more capacity than is required to accommodate any debris build up between cleaning cycles, and in the longer term, changes in the scale of the operation or use of the area. The surface of all gullies and channels should have the same slip resistance as the adjacent floor. The surface should be designed so that larger quantities of fluid can be discharged smoothly and splashing of the fluid is substantially prevented. When selecting grates or covers consider the cleaning conditions of the environment, together with chemical use. Floor drainage systems offer a number of functions broadly defined as interception conveyance barrier Product types such as gullies, slot, box and tray channels exhibit different levels of each of these functions in combination. Interception A primary function of a drain is the Interception of fluids produced in operational or cleaning processes. The property of interception can be related to the efficiency of surface fluid removal: products with high interception remove fluids over a wide area quickly. The type of drainage selected gully or channel, will depend on the nature of the operation and its requirements. Channels simplify floor gradients and offer better interception than gullies. A good example of the interception benefits of even small channel lengths is given by considering the use of a floor wipe blade - it is far easier to move cleaning liquids to a 1m channel than a single gully. Ideally drains should be positioned near the source with space allowing access for cleaning and maintenance.

16 15 Tray channel. Highest interception potential, large fluid flows, minimal or zero fluid passover. Box channel. Medium interception potential. Slot channels have a lower interception capability due to greater fluid pass-over potential however the effect is negated if the slot channel is positioned in the floor valley (low point). Gully. Lowest interception potential, but often adequate if sited at point of discharge. Tundish Intercepts surface and above surface fluids locally. They prevent splashing which is useful where the fluid is potentially hazardous; for example hot, condensate based or fluid laden with oils. 2. Drainage types Conveyance Conveyance relates to the physical movement of fluid, it may take place in a sealed system such as a pipe, or in an open system such as a Box Channel. Conveyance in a channel is related to gradient channels with built-in-fall increase conveyance rate. Conveyance of fluids across the floor ideally should be completely avoided. Box channel. Highest conveyance potential. In channel conveyance minimises drainage invert and may help in retrofit applications. Slot channels offer medium conveyance due to physical size and therefore capacity. Tray channel. Low conveyance potential limited by one piece nature of the tray. Gully. Conveyance only to ongoing drainage pipework. Barrier Prevention of fluids impacting other areas Box channel. Most adaptable system for drainage between rooms, narrow or slot systems especially are suitable for the expected high traffic load. Tundish components provide a localised barrier. Tray channel. May provide a barrier but large grating areas are not ideal for regular traffic. Gully. Not generally suitable as a barrier system unless combined with a Tundish for above surface drainage.

17 16 ACO I Drainage guide for the Commercial kitchen Types Gullies A single unitary or point drain comprising a body that houses the grating or Tundish, foul air trap, connecting spigot, and accessories such as debris baskets. Gully spigots may be vertically or horizontally orientated selection depends on building design and pipework dimensions. Gully bodies can be one piece or two-part telescopic. One piece gullies offer better hygienic performance, two-part systems allow for membrane bonding or clamping for intermediate water and damp proof layers. The gully may serve specific items of equipment (steamers, combination ovens, cold rooms etc) normally sited behind or to one side of the equipment and away from circulation routes. The Tundish is required where prevention of splashing is important. European standard for gullies is EN 1253.

18 17 Tray channels It is often difficult to accurately locate a run of several gullies to match individual outlet locations the use of a stainless steel preformed gullies with single trapped outlet overcomes the problems of location and produces a more hygienic solution. The difference between a box and tray channel is the tray channel body is a one-piece construction, which is then connected to a gully body. These systems tend to be wider and therefore offer excellent interception of large point fluid discharges. They are less suitable to areas of frequent high load. Semi-bespoke gives the convenience of specifying dimensions to match equipment. European standard for tray channels is EN Drainage types

19 18 ACO I Drainage guide for the Commercial kitchen Slot channels Slot channels offer a modular system that is both robust and discrete and ideal where gratings are not required. Suited to lower flows, they make ideal barrier systems between wet and dry areas. They are suitable for regular traffic due to minimal surface area and simple design. European standard for slot channels is EN 1253 and in addition we test and certify our channels to the stringent requirements of EN 1433.

20 19 Box channels Box channels offer a modular bolt together system that can be assembled on-site to specific requirements. Available in built-in-fall or level invert. Where regular fluid removal is required a built-in-fall system should be used. Level inverts suffice where the main function is to act as a barrier. Popular sizes are 125 and 200 mm grating widths, though the semi bespoke offering can include wider systems. A key attribute is accessibility enabling more effective cleaning - important in applications where residues are likely to accumulate in the channel. These systems are among the most versatile, offering high interception and conveyance capacities. European standard for Box Channels is EN 1253 and in addition we test and certify our channels to the stringent requirements of EN Drainage types

21 20 ACO I Drainage guide for the Commercial kitchen Tundishes The Tundish is required where prevention of splashing or aerosol formation is important. The Tundish also provides a vital air gap between the equipment and the drain, and is often the preferred method for draining of combination ovens, steaming units, boilers and cafe sets. Attached covers can be specified as a grating - to receive surface fluids, or solid to serve the connected equipment only.

22 Drainage management Functionality Once surface and equipment based liquids are intercepted and conveyed to a gully outlet it is necessary to manage the wastewater proactively to prevent problem occurrence in the building and in the receiving external drainage system. In the commercial kitchen, the focus may be on only the local drain infrastructure, however, drainage should be considered from a system perspective in that moving a problem down the line ultimately creates the potential for feedback: reduced capacity in sewers is now a recognised problem due to FOG contamination, coupled with increased rainfall intensities, sewer backflow is becoming a significant issue, especially where the facility is vulnerable because of its location. 2. Drainage types Proactive drainage management helps mitigate problems at kitchen, building, local and regional level. The net effect is more sustainable drainage a credible aim for all! Drainage management may be characterised functionally by considering: Directing liquids Managing wastewater quality Providing protection Maintainability ACO s range provides a true integrated system solution from source to sewer. As with floor drainage, many of the system component functions provide real benefit to drainage adequacy, and therefore might feature within the Prerequisite Programme (PRP) for an integrated approach. Drainage management function Direction Quality Protection Maintainability Pipe Lifting station Grease separators biological grease traps waste disposal units Backflow valves

23 22 ACO I Drainage guide for the Commercial kitchen Directing liquids Once intercepted and conveyed to outlet point the liquid must be efficiently directed. ACO Pipe provides the necessary components to manage direction for any kitchen application, safely and hygienically. When used with ACO lifting stations liquids can be pumped over significant distance with height gain. Managing wastewater quality Removal of FOG and sediments improves waste effluent quality. This is achieved by physical separation, or in combination with biological processes. Many authorities now require commercial kitchens to manage wastewater quality. Providing protection FOG treatment protects against reduced pipe capacity, possible flooding, and unhygienic conditions those suit rodents, insects, other pests and bacteria. Lifting stations and dedicated backflow valves prevent sewage ingress, and may also alert the operator of such occurrence. Maintainability As well as preventing on-going drainage problems ACO systems often incorporate crucial maintenance functions, relieving the necessity of manual intervention that often causes unhygienic conditions.

24 Types Grease separators A comprehensive range addresses all size requirements within the EN 1825 specification, with performance at or beyond the Standard s requirement. Critically, separators can be specified with varying degrees of sophistication: grease removal and cleaning maintenance can be automated, minimising disruption in the busy catering environment. Separators are tested and certified according to EN 1825 and therefore CE marked. European Standards for Grease Separators are EN 1825 Part 1 and EN 1825 Part Drainage types

25 24 ACO I Drainage guide for the Commercial kitchen Waste disposal systems The ACO Waste-Jet system combines collection, processing and disposal all in one system: the shredded food waste moves from the collection stations to the wet waste collection system using low pressure suction, once there the food waste is prepared for further treatment and to allow easy removal by recycling companies, by extracting its moisture. In bio-gas systems further secondary conversion into raw materials takes place. European Regulations for Food Waste Disposal are 1774/2002/EC, 852/2004/EC and 853/2004/EC.

26 25 Lifting plants Lifting plants are used when the grease separator is installed below the backflow level. EN 1825 requires a twin pump system to improve overall system reliability. 2. Drainage types

27 26 ACO I Drainage guide for the Commercial kitchen Pipes Stainless steel push-fit pipe system designed for grey or black water and are both temperature and chemically tolerant. ACO Pipe offers 40+ years product life thanks to stainless steel material. Easy installation and handling on site is ensured by push-fit assembly. ACO Pipe is more hygienic, robust and durable when compared to plastic pipes systems for gravity and vacuum drainage. European Standards for stainless steel pipes are EN and EN

28 27 Access covers Access covers provide quick and easy access to underground services and enable decorative floor finishes to be maintained with minimal interference. Access covers are easy to integrate in the overall design for supply and drainage installations to close off the end of the structure. Access covers are available in different load classes. They are watertight and odourtight. European standard for access covers is EN and EN Drainage types

29 28 ACO I Drainage guide for the Commercial kitchen

30 29 3. Kitchen areas 3.1 Storage and preparation area 3.2 Production area 3. Kitchen areas 3.3 Wash and disposal area

31 30 ACO I Drainage guide for the Commercial kitchen 3.1. Storage and preparation area Description Storage area The goods receiving or stores area is the main location for the receipt of all goods delivered to the catering facility including dry goods, oils, pre-packed foods, chilled & frozen foods, and even cleaning products and chemicals. The location of this area will be close to the rear of the building or service yard to accommodate the delivery vehicles and palletised loads. Care should be taken to specify load class for gully or channel - see guidance on page 100. Food storage areas will require occasional clean down as part of either a planned cleaning programme or in the case of a spillage. In most circumstances capacity of the floor drain need only accommodate low flows.the choice between channel and gully is dependent on the nature of the operation, and what functional attributes are required see the Floor Drainage section for details. Ideally the drainage unit will be accessible in the centre of an area or in entrance ways as a barrier. They should not be under immobile equipment enabling easy cleaning and maintenance of the drain itself. Gratings should be removable, but also allow mobile racks and goods trolleys to travel easily over the system without risk of grating displacement. Where Cold Storage rooms are used (coldrooms) local drainage is required for the evaporator condensate water to be discharged. The ideal solution is an adjacent drainage gully complete with a Tundish to prevent splashes and provide an air break to the main drainage.

32 31 Preparation area The preparation of food involves washing, paring or peeling, cutting, trimming or shaping and can be carried out in up to three separate areas: Vegetable preparation area: where fresh vegetables are received, stored and prepared prior to being forward to the production area. Meat/Fish preparation area: will be closest to the cooking equipment where all meat and fish can be prepared and limit cross contamination General preparation areas: will be where all other food items will be prepared and again will work closely with the production area 3. Kitchen areas All these operations produce food debris and will use water either in automated machinery or manually via a sink. Within the vegetable preparation area mobile sinks can be used to transport the prepared goods to the cooking areas. The drainage layout should ensure efficient surface water removal from within these areas using centrally located Box Channels, with simple one way floor gradients. The Box Channel s narrow section may also aid staff safety and comfort as it is less likely to be stood on whilst ensuring they will be easy to clean and maintain. Dependant upon the size of the operation slot or Box Channel s may be required at entrance way thresholds to prevent the transfer of water to corridors and other areas, thus reducing the risk of slips & falls. Well designed systems should have a debris filter at the outlet, easily removable gratings, and easily removable foul air trap.

33 32 ACO I Drainage guide for the Commercial kitchen Appliances Coldrooms A Coldroom is a pre-fabricated unit/room which stores food that requires refrigeration or freezing to maintain the product at the required temperature. The walk in coldroom or freezer will be constructed from 75mm 100mm thick modular panels. Each panel will have an insulation material foamed between two sheets of metal. Coldrooms or freezers are specified with either local or remote refrigeration systems (compressors). Local refrigeration units are normally located on the ceiling of the room with remote systems located at varying distances away from the room. Inside the room itself, normally mounted on the ceiling, will be an evaporator which will blow constant cold air around the room. The refrigeration process begins with the compressor. Gas is compressed until it becomes very hot from the increased pressure. This heated gas flows through the coils above the cold store, which allow excess heat to be released into the surrounding air. Then the gas cools down to the point where it becomes a liquid. This liquid is then forced through a device called an expansion valve which turns into a very cold, fast-moving mist, evaporating as it travels through the coils into the store. This will produce condensation within the evaporator and needs to be drained away. It is normally recommended that some form of air break is used in the drainage discharge, and this is where the ACO drainage should be used with a Tundish fitted externally. It will not be acceptable to have this point within the coldroom.

34 Typical drainage products 3. Kitchen areas ACO gully ACO Box Channel ACO pipe

35 34 ACO I Drainage guide for the Commercial kitchen Example layouts Storage area ACO Tundish Function - interception of condensate from coldroom Wash hand basin Coldroom Wall Bench Sink Unit ACO gully Function - low volume interception from various sources 4 Tier Rack ACO slot or Box Channel Function - barrier protection 4 Tier Rack Wall Bench 4 Tier Rack 4 Tier Rack 4 Tier Rack

36 35 Preparation area ACO slot or boxchannel Function - Barrier protection to other areas 3. Kitchen areas Wash hand basin Insectocutor Sink Unit Sink Unit ACO gully or Box Channel Function - low volume interception from various sources Wall Bench Vertical Bowl Chopper Meat Slicer Food Processor Wall Bench Upright Refrigerator Blast Chiller Wall Bench

37 36 ACO I Drainage guide for the Commercial kitchen 3.2 Production area Description The production area of the kitchen is the main hub of the facility and is often located at the centre of the whole catering operation. Its prime function is the cooking and finishing of food. Greasy residues may accumulate steadily on surfaces including the floor, combined with food spills this area exhibits a large potential for slips & falls. The strategic positioning of floor drainage is crucial to facilitate cleaning and aid in the removal of water that is being produced or discharged from specialist cooking equipment such as Bratt Pans, Boiling Pans & Combination Ovens. These appliances can also be used for the pouring of produce into containers so the sizing and positioning of Box Channels, Tundishes or custom made gullies for these appliances must be co-ordinated with the specialist designers or equipment manufacturers, otherwise splashing can occur causing water, grease and food debris to be spread to the surrounding floor area. The perimeter of the main cooking area would also further benefit from the strategic location of smaller gullies or channels to facilitate the cleaning of the facility at the end of the cooking period. A smaller kitchen where production volumes are not so high may rely on the specific gullies only for this purpose. Well designed systems should have the volume capacity sized to cope with appliance discharge, debris filter at outlet, easily removable non slip gratings, and easily removable foul air trap. Ladder gratings are ideal for the high point loads that might be imposed in these areas.

38 Appliances Boiling Pan A Boiling Pan is a double-jacketed cooking vessel with an inner and outer skin. Between these two skins the medium of steam and its condensation is used to provide a constant heat over the whole area of the inner vessel. This steam is created by a steam generator powered either by gas or electricity. The pan would normally have a heavily insulated outer skin, and a double jacketed lid. Although named Boiling Pan these pieces of equipment are rarely used to boil foods, but normally to gently simmer bulk dishes such as custard, sauces, soups, or stews. Most Boiling Pans will have a fixed drain tap at the bottom of the pan, which will be a wide mouthed tap for the drawing off of wet dishes such as soups, sauces and custards. It is this drain tap that needs to be suitably catered for with an with an appropriately sized and specified ACO tray channel to suit the volumes being discharged from this appliance. 3. Kitchen areas

39 38 ACO I Drainage guide for the Commercial kitchen Bratt Pan Bratt Pans are deep, rectangular cooking vessels that typically have a counter-balanced pull down lid. The heat source is direct to the underside of the vessel and can be gas or electric. A Bratt Pan is able to carry out a range of cooking functions including braising, boiling, steaming, poaching, stewing, and frying. Some models have a pressurised lid so that the vessel can be used as a pressure cooking vessel. They all have a tilting feature, which depending upon the size can be operated electrically or by a hand-driven mechanism. Food product or liquids can be poured from the Bratt Pan through a V in the front top edge of the vessel. It is this V that needs to be suitably catered for with an appropriately sized and specified ACO tray channel to suit the volumes being discharged from this appliance.

40 39 Combination Ovens The combination oven is probably one of the most versatile pieces of catering equipment any kitchen can have. A combination oven uses either a dry heat or steam injection or a combination of both to cook food in a variety of different formats. Breads, Cakes, Meat, Vegetables and Fish can all be cooked in these ovens. Regeneration (or the reheating) of food which has been pre-cooked and chilled, can rapidly be brought up to serving temperature, making combination ovens ideal for a busy banqueting or function facility, handling both ready-plated meals and multi-portion containers. Given the high temperatures that these ovens work to the drainage discharge can often be in the form of stream or close to it, and therefore drainage connections should be in Copper or Stainless Steel. It is normally recommended that some form of air break is used in the drainage discharge, and this is where the ACO drainage should be used with a Tundish fitted. In addition to the cooking fluids and steam discharge by this appliance, at the end of each day or cooking cycle the Combination Oven should run though a wash or clean down cycle using cleaning products which are then discharged to the drain via the Tundish. 3. Kitchen areas

41 40 ACO I Drainage guide for the Commercial kitchen Tilting Kettle A Tilting Kettle is most commonly used within a catering operation to prepare many different menu items, including soups, stews, gravies, puddings, sauces, pasta and rice. A Tilting Kettle can also be used to braise meats, boil large quantities of water and reheat food. Most Tilting kettles consist of an inner & outer stainless steel hemisphere which are welded together. Between these two hemispheres is a jacket into which steam is introduced. The steam entering the jacket condenses on the inner wall, which in turn transfers the heat to the food being cooked. Once the food has been cooked or reheated, the product will then need to be transferred to a large trolley/pan. This will be carried out by the entire kettle body tilting forward pouring out the liquid contents. Tilting will be achieved by either a manual handle crank or an electric push button. When the produce is poured out, this is where an ACO tray channel will need to be strategically positioned to contain any spillages. The sizing and specification of this channel or gulley is critical in supporting the volumes being discharged from the appliance.

42 Typical drainage products 3. Kitchen areas ACO tray channel ACO gully ACO pipe

43 42 ACO I Drainage guide for the Commercial kitchen Example layouts Production area Wall cookline Bench Bratt Pan ACO tray channel Primary function -high volume interception Bratt Pan Bench Bench Bench Extract canopy Bench ACO Tundish Function - interception of waste discharge from combi ovens Oven range Refrigerator Bench Sink Unit

44 43 Mid size cookline Combi oven ACO Tundish Function - low volume interception of waste discharge from combi oven Boiling pan 3. Kitchen areas ACO tray channel Primary function - high volume interception Grill Tilting kettle Oven range Bratt Pan ACO tray channel Primary function - high volume interception Bench Bratt Pan Fryer

45 44 ACO I Drainage guide for the Commercial kitchen Large scale cookline Tilting kettle Tilting kettle ACO tray channel - Primary function -high volume interception Boiling pan Boiling pan Boiling pan Bratt Pan

46 45 3. Kitchen areas

47 46 ACO I Drainage guide for the Commercial kitchen 3.3. Washing and disposal area Description Dishwash area The ware-washing area will be the wettest area of the kitchen operation. The process will involve the removal of residual food, space needed scraping, pre-soaking, rinsing and washing stages. Care must be taken to reduce the build up of fats, oils and grease (FOG) in drainage plumbing (see drainage treatment), and while grease separators offer solutions, simply wiping off food residues can have a dramatic impact on overall drainage functionality. All drainage plumbing should be routed to a grease separator designed and tested in accordance with EN 1825 parts 1 and 2, ideally situated close to source. Floor drainage also features predominantly in these areas, specifically in front of larger conveyor or flight type washers, or centrally in any dishwash or potwash area Box Channel runs are useful in front of flight type dishwashers wastewater should be treated for removal of fats, oils and grease (local regulations vary - check with your local authority) wastewater should be treated for removal of food debris and ideally sediment or debris baskets should be used at the outlet in every gully or channel run.

48 47 Disposal area This area (when included within a facility) shall be accessible from the kitchen area and also directly from the external yard to allow removal of the waste without the requirement for entering the kitchen. Ideally the disposal area will be separated from preparation and storage areas. It shall be used to store waste for short durations prior to being collected for recycling or disposal. Due to the high risk of food liquids and other substances being spilt or deposited on the floor internal & external disposal areas or rubbish stores must have a drainage gully with slip resistant gratings and the means to clean the area. External areas for waste bins should be specified for larger point loads with channels to EN 1433, and gullies to EN 124, Load Class D 400 where heavier vehicles are expected such as waste trucks. In all situations there should be access to a water supply for the cleaning down of spillages or leaks, therefore the ACO drainage gully or channel is vital. 3. Kitchen areas

49 48 ACO I Drainage guide for the Commercial kitchen Appliances Dishwashers There are many different types of dishwasher ranging from under counter units that can provide glass washing and ware washing to pass through machines, flight dishwashers and utensil washers. They all carry out the same basic function being that of washing the crockery, glasses or utensils. Under Counter These tend to be front-loading compact machines for small to moderate usage of glasses, or crockery, often fitting under a counter or on a bench in a kitchen area. Being compact leads to fast turnaround and avoiding the need for large stocking levels of crockery or glasses. Drainage can be pumped which sometimes allows them to be sited some distance from a drain point. Drainage can be a direct connection, although in many bar locations with multiple pieces of equipment discharging to a single drain, a drainage gully with a Tundish is used allowing better cleaning access. In these instances this needs to be suitably catered for with an ACO gully complete with ACO Tundish fitting.

50 49 Rack Pass Through This tends to be the next stage up in machine design, and typically has a pull-down hood. These are more powerful, faster and are manually loaded with a basket of soiled tableware. They are usually configured with stainless steel tabling either side of the dishwasher so while a basket of tableware is being washed, another basket of dirty tableware is being loaded ready to go in, and a washed basket on the other side of the hood washer is waiting to be emptied. This gives a continual cycle of plate washing. This is where you would use an ACO Gully and ACO Tray Channels. 3. Kitchen areas

51 50 ACO I Drainage guide for the Commercial kitchen Flight Dishwasher These are a semi-automatic dishwashing systems. Used in a range of locations from hospitals, and large airline catering facilities to education or staff feeding where large numbers are being fed in a short period of time. In large facilities a number of these types of machine can be linked together using a series of conveyors to create a very busy and wet operational area. In these locations drainage gullies and channels are arranged to suit the layout of the room and functionality of the system in place. For this application gullies & channels from the standard ACO range can be used, although custom made channels are also very common.

52 51 Utensil Washer These machines are specifically designed for the washing and cleaning of the utensils, pots and pans used during the cooking process. They can in addition be used for the washing of excess crockery, although the dishwashers described previously would be a more efficient machine for this purpose. A Utensil Washer is the next step up from a large double bowl pot wash sink, and by the shear nature of the operation being that of the cleaning of large pots, pans and trays a volume of water is spilled on the floor. Any utensil wash area should be equipped with a floor gully as a minimum, and more ideally with a suitably sized ACO drainage channel to ensure that the floor surface stays as dry and clean as possible. 3. Kitchen areas

53 52 ACO I Drainage guide for the Commercial kitchen Typical drainage products ACO gully ACO grease separator ACO pipe

54 Example layouts Dishwash area Large dishwash area Cleans out Flight conveyor dishwasher System Cleans out 3. Kitchen areas ACO tray channel Primary function - interception Secondary function - conveyance to common outlet ACO Box Channel or gully Function - medium volume interception from various sources conveyor Dirties in ACO Slot channel Function - General area cleaning Trolleys out

55 54 ACO I Drainage guide for the Commercial kitchen Dishwash area Small dishwash area 4 Tier Rack 4 Tier Rack 4 Tier Rack Dishwash Outlet Tabling ACO slot or box Function - barrier protection to other areas Pass through dishwash Condense Canopy ACO channel or gully Function - medium volume interception from various sources Water Softner Potwash inlet tabling with pre-spray and bowl ACO slot or box Function - barrier protection to other areas Grease Dosing Unit Scrapping and put down table

56 55 Disposal area ACO slot or box channel Function - barrier protection to other areas 3. Kitchen areas Hose reel ACO gully Function - high volume interception from hose reel ACO slot or box channel Function - barrier protection to other areas Waste compactor Waste bin Waste bin ACO load class D4OO gully Function - medium volume interception from various sources

57 56 ACO I Drainage guide for the Commercial kitchen

58 57 4. Product portfolio 4.1 ACO gullies 4.2 ACO tray channels 4.3 ACO slot channels 4.4 ACO Box Channels 4.5 ACO gratings 4. Product portfolio 4.6 ACO grease separators 4.7 ACO waste disposal systems 4.8 ACO lifting plants 4.9 ACO pipes 4.10 ACO access covers

59 58 ACO I Drainage guide for the Commercial kitchen 4.1. ACO gullies ACO stainless steel gullies are designed to be used in commercial applications where hygiene, durability and performance requirements are paramount. ACO applies standards reserved for food contact surfaces EN 1672 and EN ISO to the gully design. ACO gullies are characteristic with: Deep-drawn body ensuring smooth contours eliminating crevices that can nest dangerous bacteria. All radiuses larger than 3mm which greatly increases the cleaning effectiveness. Dry sump design, completely drainable - eliminating potential problems of bacteria growth. Edge in-fill ensuring stable and durable transmission between the gully and surrounding floor and helping to minimise the risk of floor cracks that prevents bacteria growth. ACO gullies are available in a number of versions featuring different flow rates (up to 6.3l/s), sizes, spigot outlet diameters and grating designs to suit various applications. The floor construction and depth together with the use of any waterproofing membrane play an important role in the selection of the appropriate type of gully. ACO offers gully configurations as shown below. Fixed height gullies are convenient, freestanding units suitable for cementitious, resin or tiled floors. Telescopic gullies can be installed either with ACO gully tops or with ACO stainless steel linear drainage channels in most flooring constructions, including floors with waterproofing membranes. All ACO gullies are available with vertical or horizontal spigot outlets. European Standard for gullies: ACO tests gullies to EN 1253 Gullies for buildings

60 59 Gully types Fixed height gully Telescopic gully 4. Product portfolio Fixed height gully Telescopic gully Round gully top for vinyl flooring Gully top for tiled, resin or cementious flooring Gully top for thin-bed applications

61 60 ACO I Drainage guide for the Commercial kitchen Features All radiuses larger than 3mm which greatly increases cleaning effectiveness Edge in-fill ensures stable and durable transmission between the gully and surrounding floor and helps to minimise risk of floor cracks which could harbour micro-organism Deep-drawn body ensures smooth contours eliminating crevices that can nest dangerous bacteria Dry sump design, completely drainable - eliminating stagnant water, smells, microbial growth and potential chemical hazards. Please find detailed information and relevant article numbers in ACO gully catalogue or at

62 ACO tray channels ACO tray channels are designed to be used in commercial applications where hygiene, durability and performance requirements are paramount. ACO tray channels are available in number of different versions featuring different channel volume, flow rates, size and spigot outlet diameter to suit various applications. In all cases the base of the tray incorporates a gradient to ensure rapid liquid removal minimising debris build up. The floor construction and depth together with use of any waterproofing membrane play an important role in selection of the appropriate type of ACO tray channel. ACO tray channels are available in a number of versions featuring different channel edges, sizes, capacity and spigot outlet diameters to suit various applications. 4. Product portfolio mm mm mm ø mm European Standard for tray channels: ACO tests tray channels to EN 1253 Gullies for buildings

63 62 ACO I Drainage guide for the Commercial kitchen Tray channel types Standard type for concrete, tiled or resin floor Extended type for tiled floor Vinyl type for vinyl floor Telescopic type for tiled floor

64 63 Tray channel components Grate Silt basket Foul Air Trap 4. Product portfolio Tray channel Friction ring Gully Please find detailed information and relevant article numbers in ACO tray channel catalogue or at

65 64 ACO I Drainage guide for the Commercial kitchen 4.3. ACO Modular 125 (Box Channels) ACO Box Channel systems enable simple selection and specification from a wide range of components. These modular or bespoke systems are extremely adaptable to specific circumstances, and are ideal where existing equipment has to be accommodated. They offer excellent waste water conveyance and interception properties - and are ideally suited to areas where medium to high volumes of liquids are present. Removable gratings facilitate cleaning and maintenance, and built-in-falls with a 'V' channel base profile help minimise sediment build up in the channel. Box channels should preferably be specified with a gradient - level inverts can be provided but are not preferred. ACO slot channel systems consist of various straight channels (length up to 6000mm), corner and branch units and outlets. This system is suitable for various applications. Features Stainless steel construction for durability and long life V-bottomed profiled channel for enhanced flow efficiency at low flow rates and for improved self cleaning performance Modular concept allows specification of standard channel units to surround machinery and fit within existing tiling patterns Wide choice of grates to suit the application and load class Hydraulic capacity calculation for linear channels is a complex process that can require computational analysis. ACO provides this service free of charge. European Standards for slot channels: ACO tests slot channels to EN 1253 Gullies for buildings and EN 1433 Drainage channels for vehicular and pedestrian areas.

66 65 Slot channel components Product portfolio Outlet unit 6 Grating 2 Level invert and sloping invert channel 7 Gully 3 Corner unit 8 Silt basket 4 Branch unit 9 Foul air trap 5 End plate Detailed information for Box Channel systems available on

67 66 ACO I Drainage guide for the Commercial kitchen 4.4. ACO AS601 (Slot Channels) ACO slot channel systems with 20mm surface aperture offer simple and effective waste water interception and conveyance suitable for a wide range of applications where accessibility to the channel is not critical - for example any area where low volumes of fluid are expected without significant food debris. Combined with a gully, they provide effective central washdown drainage solutions. Through its simple construction the system is reliable and robust - with no potential grating loss where that might otherwise present a hazard. Slot channels should preferably be specified with a gradient - level inverts can be provided but are not preferred. ACO slot channel systems consist of various straight channels (length up to 6000 mm), corner and branch units and outlets. This system is suitable for various applications. Features Stainless steel construction for durability and long life V-bottomed profiled channel for enhanced flow efficiency at low flow rates and for improved self cleaning performance Modular concept allows specification of standard channel units to surround machinery and fit within existing tiling patterns Hydraulic capacity calculation for linear channels is a complex process that can require computational analysis. ACO provides this service free of charge. European Standards for Box Channels: ACO tests slot channels to EN 1253 Gullies for buildings and EN 1433 Drainage channels for vehicular and pedestrian areas.

68 67 Box channel components 6 1 Outlet unit Level invert and sloping invert channel Corner unit Grating Gully Silt basket Product portfolio 7 Foul air trap 1 Detailed information for slot channel systems available on to to Up to 3000 Maximum length as standard Up to 3000 Maximum length as standard Please Note: If channel depth is greater than channel bore then a V bottom will be incorporated. All dimensions are in mm.

69 68 ACO I Drainage guide for the Commercial kitchen 4. 5 G r a t i n g s Standard grating overview Grating Aditional slip resistant feature ACO gully ACO tray channel ACO slot channel ACO Box Channel Load class up to Mesh grating C250 L15 Ladder grating C250 L15 ARLA grating L15 Vulcano grating B125 Slot cover Quadrato Heelsafe Perforated grating Plastic grating Composite grating M125 B125 A15 C250 Load class A15, B125, C250 according to EN 1433 and EN 124, Load class L15, M125 according to EN 1253

70 69 Slip resistance ACO offers gratings with additional slip resistance feature - slip resistant gratings. Plain grating: to be used in areas with reduced demand for slip resistance for example where trolleys are turning. Slip resistant grating: to be used in all areas where there is an increased risk of accident caused by slipping 4. Product portfolio Plain grating Slip resistant grating Please find detailed information and relevant article numbers in ACO gully, ACO tray channel and ACO slot and box channel catalogue or at

71 70 ACO I Drainage guide for the Commercial kitchen 4.6. ACO grease separators Many commercial and industrial food processing and production facilities generate waste water contaminated with animal and /or vegetable fats, oil and grease. This particularly applies to large kitchens in restaurants, hotels and canteen, and also abattoirs. Fats, oils and grease (FOGs) from these applications can cause pipe blockages, corrosion and ultimately malfunction of public sewage networks. These risks give rise to considerable water damage and repair costs not to mention the hygienic and environmental issues resulting in flooding of the food preparation area and the increased potential for rodent infestation. Grease separators (or grease interceptors) solve these problems with an effective functional principle: gravity separation. Functional principal of a grease separator

72 71 ACO Grease separators according to European Standard (EN) 1825 rely on the relative density naturally present in the influent. FOGs, whilst wide ranging in relative density, are always less dense than water and naturally float on the surface of the water within the separator unit. Similarly, solid particulates common to most cooking processes are denser than water and sink to the separator base. The Standard prescribes the various separator compartment dimensions, which are a function of the required flow through the separator. Conveniently, the design section of the Standard allows the specifier to arrive at a single figure expressed as nominal size (NS), which relates to the flow through the separator in litres per second. A secondary figure is also derived which relates specifically to the size of the solids retention compartment thus a typical specification would read NS relating to a separator capable of sustaining 7 litres/second flow and with solids capacity of 700 litres. Disposal types FOGs and solids are retained inside the grease separator. FOGs and solids must be periodically removed from the grease separator to prevent blockage. Usually, certified recycling companies use disposal trucks to empty the entire contents of the separator. The choice of the disposal types mainly depends on two questions: Are suction trucks available? I s the interruption of operations (for example: 24-hour kitchen) permissible? Therefore there are two types of grease separators available: Grease separators for complete disposal (full disposal) and grease separators for partial disposal (fresh grease separators). 4. Product portfolio