1 Food Safety Matters Webinar Series The webinar will begin shortly Audio will be provided through your computer If your computer does not have audio, phone lines are available: Phone number: 1-877-668-4493 Access code: 663 770 448 Technical Difficulties? Contact WebEx Technical Support: 1-866-229-3239
2 Food Safety Matters Webinar Series The webinar will begin shortly Technical Difficulties? Contact WebEx Technical Support: 1-866-229-3239
3 Food Safety Matters Webinar Series Ecolab Video
4 Food Safety Matters Webinar Series Thank you for joining us. If your computer does not have audio, phone lines are available: Phone number: 1-877-668-4493 Access code: 663 770 448 Technical Difficulties? Contact WebEx Technical Support: 1-866-229-3239
5 Food Safety Matters Webinar Series Our Featured Speaker This Month: Frank Bocci, Principal Technical Service Specialist II Food Retail Services at Ecolab If you have a question for the Presenter, type your question using the online Q&A feature.
What is a Mechanical WareWasher? (aka Dish Machine / Utensil Washer)
A Dish Machine is a 3-Compartment Sink In A Box
Mechanical warewashing provides an alternative to the 3-step manual cleaning process of Wash Rinse - & Sanitize typically performed at the 3-Comp Sink. When correctly utilized a properly operating dish machine can: Reduce labor in time spent @ the 3-Comp Sink Increase crew productivity as it relates to their ability to perform other activities in the Restaurant / Operation Ensure wares have been properly washed and sanitized
High Temp vs. Low Temp Dish Machines What s the difference? High Temperature Dish Machines: 1.Final rinse water sprayed on the Ware must be delivered at a temperature of 180⁰ - 194⁰ F. 2.Final Rinse Water is heated to this temperature by a Booster Heater that is either an integral component of the Dish Machine, or is an external Device plumbed-in upstream of the Dish Machine. 3.Typically, high temperature Dish Machines require the water in the Wash Tank to be maintained at a minimum temperature of 150⁰ F. This is achieved by a Heating Element located within the Wash Tank of the Dish Machine. 4.The ultimate goal is to raise the surface temperature of the Ware to 165⁰ F at the completion of the Final Rinse to achieve Sanitization.
High Temp vs. Low Temp Dish Machines What s the difference? Low Temperature Dish Machines: 1. A Chemical Sanitizing Agent, typically Chlorine, (Sodium Hypochlorite) at a minimum concentration of 50 PPM, is mixed in with the Final Rinse Water and sprayed on to the Ware during the Final Rinse Cycle. 2. Typically, the Temperature of the water & Chlorine Sanitizer mixture delivered / sprayed onto the Ware s during Final Rinse must be maintained at a temperature no lower than 120⁰. 3. Low Temperature, Chemical Sanitizing Dish Machines, require that the Wash Water be maintained at a minimum Temperature of 120⁰ F. 4.Typically, Low Temp Dish Machines do not have any type of integrated Heating Element s in their Wash Tank. They receive their Hot Water from a domestic Hot Water Heater.
A Dish Machine is a Dish Machine is a Dish Machine! There are actually dozens of makes and models They come in various shapes and sizes They are referenced as Ware Washers, Dish Machines, Dish Washers, Utensil Washers, Rack Washers, etc. At the end of the day, regardless of their physical appearance or what they re referenced as, they all perform the same 3 step process of Wash Rinse - & Sanitize
Machine Types Stationary Rack Conveyor (Rack) Conveyor (Flight Type) Utensil Washers
Stationary Rack Machine Types As the name implies, Wares are arranged on a Rack that is manually pushed into the Machine, where they sit in a static position throughout the Wash-Rinse- & Sanitize cycle.
Conveyor Machine Types Wares, arranged on a Rack, are propelled through the various stages of the Wash- Rinse- & Sanitize process via a motorized Conveyor, which is an integrated part of the Dish Machine. Conveyor Type Unit s may also have additional sections that include pre-wash & prerinse compartment s.
Flight Type Machine Types In a Flight Type Unit no Racks are used. The Machines moving Conveyor is configured with Peg s that are used for arrangement of the various pieces of Ware that will be run through the Unit.
Machine Types Operational Differences Retained Wash Solution: A dedicated source of Hot Water and Detergent maintained at a specific temperature by a Heating Element within the Wash Tank of the Dish Machine. Wash Water is pumped under pressure through the Wash Arm s and onto the Ware. Most often associated with High Temp Dish Machines. Wash Tank Solution is refreshed every time the Machine goes through the Final Rinse Cycle. Rinse Water is always fresh potable water. Water level within the Wash Tank is maintained at a constant via use of an Overflow within the Wash Tank
Stationary Rack 1.Rack of Ware s placed into machine and cycle started Retained Wash Solution Wash Cycle 180 0 F Rinse Water DISH RACK DISH TABLE DISH TABLE SCRAP TRAYS 3. Wash solution drains back into tank, passing thru scrap trays WASH PUMP 2. Wash pump is activated, draws wash solution out if tank, thru wash arms/nozzles. Sprayed onto Ware s 4. Solution continues to be recirculated throughout wash cycle.
Stationary Rack 2. Timer opens 180 0 water solenoid to allow rinse water in rinse arms. Sprays over Ware s, drains into tank Retained Wash Solution Rinse Cycle 180 0 F Rinse Water DISH RACK DISH TABLE DISH TABLE SCRAP TRAYS 3. Rinse water drains into wash tank, dilutes wash solution, level rises and overflows OVERFLOW TO DRAIN WASH PUMP 1. At end of Wash Cycle, pump stops, delays to drain solution from Ware s, rinse starts. 4. Dish Rack removed onto Dish Table to air dry.
Single Tank Conveyor 1. Rack of Ware s inserted into machine, goes thru wash then final rinse out clean DISH FLOW LEFT TO RIGHT 180 0 F FINAL RINSE WATER DISH RACK DISH RACK DISH RACK DISH RACK SOILED DISH TABLE 2. Wash water returns to wash tank after spraying Ware s. PUMP WASH TANK CLEAN DISH TABLE 3. Rinse water flows to wash tank, diluting wash solution, level rises, tank overflows OVERFLOW TO DRAIN
Machine Types Operational Differences Dump & Fill Type: At the conclusion of the Wash Cycle, a Drain Solenoid open s allowing the full content s of the Wash Tank to empty. After a brief period of Dwell, allowing for full evacuation of Wash Solution, a Solenoid Valve opens allowing fresh potable water to enter the Machine. This fresh potable water is then utilized for the Final Rinse. Dump & Fill Machines are typically Low-Temp Machines. In a Low-Temp Machine, a Chemical Sanitizing Agent (usually Sodium Hypochlorite) is introduced along with the fresh potable Rinse Water. The Final Rinse Solution becomes the Wash Water for the next Cycle.
Stationary Rack SOLENOID VALVE Dump And Fill Wash Cycle Fill Water DISH RACK DISH TABLE DISH TABLE SCRAP TRAYS 2. Wash solution drains back into tank, passing thru scrap trays WASH PUMP 1. Machine fills (1.5-2 gal.), detergent added, pump draws wash solution from tank, thru arms/nozzles to spray ware s. 4. Solution continues to be re-circulated throughout wash cycle, 45 seconds avg.
Stationary Rack SOLENOID VALVE Dump And Fill Drain Fill Water DISH RACK DISH TABLE DISH TABLE SCRAP TRAYS 2. Wash Solution drains from tank, arms, ware s. WASH PUMP 1. When Wash Cycle done, pump stops, drain valve opens DRAIN
Stationary Rack SOLENOID VALVE Dump And Fill Rinse Cycle Fill Water DISH RACK DISH TABLE DISH TABLE SCRAP TRAYS 2. Wash solution drains back into tank, passing thru scrap trays WASH PUMP 1. Machine again fills (1.5-2 gal.), sanitizer may be added, pump draws rinse solution from tank, thru arms/nozzles to spray ware s. 3. Solution continues to be re-circulated throughout wash cycle, 30 seconds avg. Rinse solution may be drained or retained per model.
Best Practices & The 5 Factors of Cleaning
5 Factors that contribute to Clean Ware Chemical Action 20% Time 20% Procedures 20% Temperature 20% Pressure 20%
5 Factors -- Debit / Credit Dirty Dishes! 8% Time 20% Chemical Action 30% Temperature 14% Procedures 14% Pressure 14%
FIVE FACTORS OF CLEANING Procedures Improper procedures can impact all the other factors, reducing the overall effectiveness of your cleaning operation. Procedure is the one thing that the end-user has full control over! Proper Procedures include: Pre-Scraping / Pre-Rinsing Correct utilization of the Dish Rack
FIVE FACTORS OF CLEANING Temperature Improper / lower than specified temperature, will impact product performance and overall effectiveness of the cleaning & sanitization process in a WareWash Unit.
FIVE FACTORS OF CLEANING Pressure/Mechanical Action Proper pressure in WareWashing operations increases the ability of the wash solution to remove Soil. This ties directly to proper procedures, as well as overall Dish Machine cleanliness!
FIVE FACTORS OF CLEANING Chemical Action Only use Products specifically formulated for Mechanical WareWashing. Certain Wares, such as those made of Aluminum and Pewter, require use of a Detergent Product that is Metal Safe.
FIVE FACTORS OF CLEANING ttime For Wares that are heavily soiled, or have baked-on food soil, allowing some period of time for pre-soaking can be prove to be very advantageous. Some WareWash Machine Models allow the end-user to vary the length of the Wash Cycle, thus maximizing the effectiveness of the Washing process.
Best Practices Operational Checks Care & Maintenance
Operational Checks Gauges oall Dish Machines have Analog or Digital Readout Gauges which provide the end-user with a quick and easy method for verifying Temperatures & Pressure. oby law, Dish Machines must have working Gauges that indicate the temperature of the Wash Tank, as well as the Final Rinse in Hot Water Sanitizing Units. o In the case of a Hot Water Sanitizing Unit, a working Pressure Gauge must also be clearly visible.
Temperature Gauges are prominently displayed with recommended operating temperatures posted in either close proximity to the Gauge or on a tag and/or placard somewhere on the Dish Machine itself.
Per the Food Code: A working Pressure Measuring Device (a Gauge) must be clearly visible. This Gauge will indicate the pressure at which the Final Rinse water is being delivered at. The acceptable Range is between 15 25 PSI with 20 PSI being the optimum pressure. Final Rinse Water delivered at 20 PSI is also how most Dish Machine manufacturers calculate the water usage per cycle. Static Pressure (at rest) Final Rinse Pressure (flowing)
Operational Checks Wash Arms & Rinse Jet s o Clogged Wash Arms and Rinse Jet s will result in an ineffective wash, and more critically, Wares that may not be Sanitized. o Clogged or partially blocked Wash Arm s are usually a clear indicator that proper pre-scrapping procedures are not being adhered to. o As the Final Rinse is always fresh potable water, clogged Final Rinse Jet s are typically a result of sediment, debris, or mineral scale build-up due to hard water. o All Dish Machines have Wash Arm s and Rinse Jet s that may be removed for periodic cleaning.
Rinse Arms, Jet s & Nozzle Regardless of how they are configured or how they might physically appear, all Wash & Rinse Arms and/or Jet s may be removed for cleaning
Operational Checks Curtains ocurtains retain heat in machine - Low temperature = rewash - Missing curtains = high energy cost o Prevent water transfer - Excess dilution = detergent cost - Proper placement of curtain s is vital o Detergent splash-over into rinse - Residual alkalinity = rewash o Curtains should be removed to be cleaned. - De-limed in hard water areas o Proactive cleaning and de-liming will extend the useful life of the Curtain.
Operational Checks Rinse Arm Alignment (Conveyor Machines) o Improperly aligned Rinse Arms may prevent full coverage of the Final Rinse Water on all surfaces of the Ware. Applicable in both Hot Water & Chemical Sanitizing Dish Machines. o May also contribute to unnecessary dilution of the Detergent Solution in the Wash Tank, which ultimately contributes to higher Product usage. o A simple observation by the end-user can quickly determine if the Rinse Arms are misaligned.
Curtain Improperly Aligned Rinse Jets Div. Pan Wash Tank
Curtain Properly Aligned Rinse Jets Div. Pan Wash Tank
Operational Checks Preventive Maintenance Cleaning Daily oevery operation is different. A schedule for Draining, Flushing, and Re-filling the Dish Machine should be predicated on: The frequency at which the Dish Machine is used throughout the day. The types of Ware the Dish Machine is used for. How diligently the Dish Washer adheres to proper pre-scrapping of Wares that are passed through the Dish Machine.
Teach & Train Excess soil increases product consumption and contributes to poor results
Operational Checks Preventive Maintenance Cleaning Daily & Beyond o Deliming Predicated on the Water Hardness in your area, scheduled & routine de-liming can provide financial and operational benefits. Reduced water and energy costs. (¼ of Lime Scale causes a Heating Element to use 39% more energy!) Improved equipment performance Reduced equipment maintenance and/or replacement costs and downtime.
Operational Checks Preventive Maintenance Cleaning Daily & Beyond osimple, common sense, visual observations of the Dish Machine interior & exterior: Are interior surfaces clean and free of food debris or greasy build-up? Are Wash & Rinse Arms clean and do they spin freely? Are Sensors and Heating Element s within the Dish Machine Compartment s clean and free of food or lime scale build-up? In those Unit s that utilize Curtains, are the Curtains in-place, clean, and properly positioned within the Dish Machine?
Detergent Sensor Drain Overflow Tube Temperature Probe Upper Limit Switch Low Water Sensor Heater Element Safety Switch Pump Intake
Final Rinse Activator Turn on just as leading edge of rack enters rinse spray Turn off as trailing edge passes Be sure rinse always shuts off Efficient adjustment can cut costs by over 20% (chemicals, energy, water)
Conveyors: An improperly adjusted or worn Conveyor can impact efficiency! Check for damaged or missing conveyor dogs Check all conveyor dogs alignment with racks Check free play in conveyor bushings -Excessive wear slows rack - Increases rinse-on time
Racks Often overlooked, racks are a critical part of the overall WareWashing Process, especially in a Conveyor Machine. o Worn or damaged Racks may not not efficiently move through the Dish Machine, resulting in excessive wash time as well as wasted hot water and energy if hung-up in the Final Rinse.
Summary A properly operating and maintained automatic WareWashing Machine can: oprovide proven operational efficiency and labor savings oensure clean & sanitized wares Maintaining a WareWasher to ensure maximum benefit is no more difficult than: operforming quick and simple visual checks of the Unit at the beginning of each shift to verify proper operation & temp s. oensuring crew members are instructed as to proper up-front procedures, i.e. pre-scrapping and pre-soaking where appropriate. oroutinely practicing proper cleaning and preventive maintenance to ensure the Dish Machine is always operating at 100% operational efficiency.
Questions? 51
Food Safety Matters Webinar Series Thank you for joining us today
Food Safety Matters Webinar Series A recording of this presentation will be available Friday, Oct. 18 at: www.youtube.com/foodsafetynet
Food Safety Matters Webinar Series November Food Safety Webinar: Tuesday, Nov. 19 Seasonal Special: Understanding & Preparing for Influenza Webinar Tuesday, Oct. 22 Visit http://www.ecolab.com/media-center/webinars for more information
Food Safety Matters Webinar Series Thank you for joining us today, we look forward to speaking with you on Tuesday, Oct. 22 and Nov. 19, 2013.