FE&S 2004-2005 Product Knowledge Guide: Sanitation & Safety Equipment
By The Editors -- Foodservice Equipment & Supplies, 9/1/2004
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Cleaning Supplies
Types: Cleaning supplies are available in many varieties, including wet mops, mop handles, mop buckets, mop wringers, brooms and brushes, dustpans, utility handles, floor squeegees, scouring pads, grill cleaners, plastic spray bottles and buckets.
Capacities/Functions: Mop heads provide a variety of yarns among which operators can choose. Cotton offers good absorption and retention, low cost and limited shrinkage, making it appropriate for general uses. Rayon mop heads are designed for quick absorption and release; they also dry fast, are mildew-resistant and shed less lint. These mop heads are most often used to apply liquids, including finishes and disinfectants. Other synthetic mop heads are designed to offer superior tensile strength while shedding no lint, making them best for use on rough surfaces. Blends are designed to offer a balance of price, performance and durability.
Mop wringers assist in mopping functions by attaching to the outside of a mop bucket to make wringing mop heads easier. Wringers are designed to accommodate 8-oz. to 36-oz. mop heads and are available in side-press and down-press designs. Both are offered in a choice of durable plastic or zinc plated.
Three types of brooms/brushes are most commonly used in foodservices: lobby-angle brooms, deck brushes and floor sweeps. Lobby brooms are typically 360 in width and used for light cleanups throughout the day. Deck brushes are 100 to 120 in width and most often used for rugged scrubbing. Floor sweeps' 180 to 360 widths allow for larger floor coverage when sweeping. Floor sweeps are most appropriate for fine to medium cleanups.
Floor squeegees are available in metal or plastic, straight or curved models. Floor squeegees are used to remove a liquid from a kitchen floor once it has been sprayed down. Handles are sold separately.
Scouring pads are offered in three weights: light-duty, medium-duty and heavy-duty. Light-duty pads work best on most ceramic, chrome, porcelain, stainless-steel and painted surfaces. Medium-duty pads are designed for daily cleaning of pots and pans, dishes, utensils and equipment. Heavy-duty pads are very abrasive and usually are only used for removing baked-on deposits and scuff marks.
A "grill brick" is a cleaning pad that is designed to clean residue safely and effectively from a hot grill without scratching the surface. Griddle screens are used for light cleaning or after cleaning with a griddle brick. Griddle pads are designed for light cleaning and polishing and can be used on a warm grill with a griddle screen and holder.
Plastic spray bottles are used to hold cleaning solutions and are usually available in sizes of 16 oz. to 32 oz.
Air Curtains & Air Doors
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Types: Air curtains/doors may use recirculating or non-recirculating air. Recirculating air doors are designed to prevent the loss of heating and air conditioning efficiently while maintaining interior climates. They are used primarily in foodservice establishments where doors need to be left open. Non-recirculating air doors are more commonly used by operators because of ease of installation and lower costs. They are used to separate two environments and/or prevent flying insects from entering a foodservice facility. Such units can be applied to openings as various in size and use as drive-through windows and loading docks.
Capacities/Footprints: Air curtains, mounted above a door either on the interior or exterior, are available for doors from 39 to 129 wide, and can now be custom-manufactured for doors up to 169 wide and 209 high.
Energy Source(s): Air doors create an invisible air seal generated by high-efficiency, direct-driven centrifugal fans that compress air inside the unit and release it through a directional nozzle outlet with a pressure designed to be powerful enough to stop winds of up to 25 MPH. An air curtain used for repelling flying insects requires a higher velocity of air than one designed for environmental preservation.
Standard Features: Air curtains for both types of applications are available with adjustable air velocities and can be ordered unheated or equipped with electric, steam or hot-water heating units. Industrial models are available with gas-fired heating options. In certain situations, an air-door system must be hung from a ceiling, regardless of the opening it will be shielding. When such a case does occur, manufacturers offer special bracket systems for installation. Units can also be equipped with separate control switches that can determine a system's thermostat and air pressure, among other factors. For facilities that are prone to vandalism, such as schools and prisons, some air door systems can be outfitted with tamper-resistant features.
New Features/Technology/Options: An automatic door switch can now be specified to control operation of an air curtain when a door opens. A time-delay control can also be installed in high-traffic areas. In addition, some operators are now using air curtains to separate smoking and non-smoking areas inside their facilities. If an air curtain is installed over a sliding door (such as those found in many drive-through windows) an automatic roller-door switch can be added. Such a switch turns the air curtain on when a portal is opened and off when it is closed. Similar switches are available for hinged doors, as well. It is not recommended, however, that such features be combined with air doors equipped with heating systems. The amount of time such systems would be active is limited, thus rendering the heating process ineffective.
Prime Functions: Air curtains are used to keep two environments separate by keeping inside conditioned or heated air untainted by outside air, and to prevent the intrusion of flying insects, dust and other airborne contaminants. Air curtains also facilitate free-flowing traffic in facilities, as well as unobstructed vision.
Key Kitchen Applications: Air curtains are used to control insects and aromas in kitchens, as well as above dock doors, walk-in coolers, drive-up windows or any opening susceptible to energy loss or temperature variation. Air curtains used for insect control should be mounted on a kitchen doorway's exterior. For optimum protection, an environmental control unit should be mounted on the interior of a doorway, drawing in conditioned air through an intake screen and discharging it through a nozzle to create the necessary air seal. While air curtains and doors can and do serve multiple functions, units can be ordered with particular features and installed at a wide variety of angles to make them more effective for specific applications. For example, an air door that is primarily intended to prevent pests from entering a facility should blow air at a higher velocity than other units, and should be installed at an angle that allows it to blow outward.
Sales Guidelines: With food safety a widespread concern, DSRs should stress that air doors and curtains can help to reduce the risk of foodborne illness by preventing insects from entering a kitchen or dining area. Because they can help maintain heated or conditioned air temperatures, air curtains and doors also offer operational savings and can pay for themselves in as little as two years. When selling an air curtain or door, DSRs should be sure to understand exactly where it will be installed in relation to staff and, especially, the front of the house. This is because different units have different noise outputs, which can affect an operation's atmosphere and customers' dining experiences.
DSRs should further be aware that units that draw air from inside a building but expel some air outside can create what is called "negative pressure," which can make opening doors difficult.
Doorways utilized by customers should not be equipped with high-velocity air-door systems, as they can create an unpleasant experience when coming into an establishment. DSRs should suggest, however, that systems installed at customer entrances and exits include a heating function that can be turned on during colder weather.
Maintenance Requirements: Air curtains should be cleaned regularly for best performance. Air-cleaning filters are available for many air curtains. These filters, which are often constructed of washable aluminum mesh and are hence reusable, offer the benefits of both improving air quality and reducing odors.
Food Safety & Sanitation Essentials: Air curtains prevent houseflies and other pests from entering foodservice facilities, helping to eliminate potential exposure to diseases. The U.S. Food and Drug Administration specifically recommends the use of air curtains for the exclusion of insects. Several states have additionally enacted legislation regarding the mandatory installation of air curtains at specified openings in food production facilities.
Disposers/Pulpers & Compactors
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Types: Disposers with rotor-fixed cutting teeth are the most common variety, although some may be equipped with swivel cutting teeth or a hammer mill-type grinder. In all instances, a cutter rotates at a high speed inside a stationary shredder ring. As centrifugal force moves foods through a shredder, waste is then washed into the lower area of a unit and down a drain or into a compactor unit.
While disposers can be operated on their own, waste compactors (or pulpers) should not be operated without a disposer. Waste compactors are offered in a variety of styles and have motors ranging from 1 hp to 5 hp.
Capacities/Footprints: Disposers are manufactured with motors ranging from 3/4 hp up to 10 hp. Horsepower determines units' shredding capability, as well as their capacity for continuous operation. Light-duty disposers are intended for use in delis and convenience stores. Heavy-duty, small-, medium- and large-capacity disposers are designed to meet the needs of larger operations. The body size of a disposer determines its waste-handling capacity. The larger the body, the greater the waste capacity. Light-duty disposers are the smallest commercial disposers. They are approximately 140 in height. Larger disposers range in size from 170 high to approximately 230 in height. Compactors are used in conjunction with disposers. Compactors are available in 1, 2, 3 and 5 hp, handling from 300 to 900 lbs. of waste per hour.
Energy Source(s): Disposers and compactors can both be operated with and are available in the following voltages — 115, 208, 230 and 460 volts.
Standard Features: A standard electrical wall switch can be used to operate light-duty disposers. Larger disposers have a variety of electronic controls that end-users may choose among. The most common electronic control today is a manual reverse switch that allows shredding in both directions, which can help unjam a machine and prolong the life of a disposer.
All compactors are supplied with a standard manual switch control panel. Water controls are offered with all disposers and compactors to regulate the amount of water going in and out of units. A siphon breaker prevents backflow, while a solenoid valve ensures that water runs straight through a disposer. Flow control valves are designed to provide the correct amount of water for each size model.
A motor is the heart of a disposer. To ensure longer use-life, motors are enclosed and cooled by a controlled airflow. Most motors are also protected from water damage by triple lip seals. A secondary spring-loaded oil seal available on many models provides extra security against water damage and loss of grease. Disposer housings are available in a variety of durable, corrosion-resistant materials ranging from hardened aluminum to stainless steel. Some disposers are coated or plated.
Designed with the correctional market in mind, some disposers are built to sit several inches offset from a sink drain. Such a design helps to forestall tampering. There are also offset attachments that perform the same function that can be used in conjunction with most disposers. Similarly, most units can be equipped with tamper-proof screws.
Compactors are usually constructed of stainless steel and are designed to produce an 85% reduction of waste volume. A 5-hp compactor features a 1/2-hp recirculation pump to reduce water consumption. Five-hp compactors' water consumption is 10 gals. per minute. One-, 2- and 3-hp compactors consume 3 gals. per minute. Among the options currently available for disposers is an unjamming wrench, which staff can insert into a jammed machine and twist to dislodge stuck objects. Also available for purchase in conjunction with disposers are magnets that are designed to prevent flatware and other metallic objects from falling into a unit.
In the safety realm, many disposers can also be purchased with guards that prevent individuals from reaching into a working model.
New Features/Technology/Options: Some pulper and disposer controls now offer water- and energy-saving features. These use load-sensing electronics and timers to regulate water flow and run times. Automatic reversing controls now available for disposers start a unit in the opposite direction every time it is activated.
A new product that is available on the market that can be used in conjunction with pulpers is an organic-waste disposal system. The system, which is completely self-contained, decomposes food waste into liquid in a matter of days by applying heat, water and motion to organic waste held in a central drum. The resulting liquid can then be disposed of through existing sewage treatment facilities or, even, because it is nutrient-rich, be added as a supplement to irrigation and plant-watering systems. Such a system is designed practically to eliminate on-site food waste, reducing the risks posed by cross-contamination, pests and other health threats, and also reduces waste removal requirements.
Key Kitchen Applications: Commercial disposers and pulpers are most commonly found in food prep and warewashing areas. They are designed to provide maximum shredding for the disposal of food and non-food waste.
Sales Guidelines: DSRs should inform their operator customers that a disposer/pulper/compactor system can result in significant savings in water use, sewage costs and waste removal charges. By immediately removing and/or isolating food waste from the back-of-the-house area, they also help to eliminate pests and reduce the labor needed to haul trash out to a dumpster.
Some municipalities have restrictions on waste disposers. DSRs should encourage clients in such areas to consider waste collection systems. These systems allow water-soluable waste to be washed down the drain while gathering solid food waste in a trough, for later disposal into the trash.
Maintenance Requirements: Disposers are designed to be very low-maintenance equipment. After shredding, waste water must simply be run through a unit to eliminate clogging.
Compactors are also intended to be low maintenance and easy to clean. No tools are required to clean a compactor. Staff should simply take apart and clean the pulper screen once a day.
Food Safety & Sanitation Essentials: Disposers and compactors allow for speedy elimination of waste, assisting in insect and rodent control.
Protective Lighting
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Types: Protective lighting is designed in many types, shapes, sizes and watts to offer maximum options in safe illumination. Protective lighting includes standard fluorescents, high output (HO), very high output (VHO), U-shaped fluorescents, black lights and Teflon-coated incandescent lamps.
Capacities/Footprints: Standard fluorescents are offered in full wattage, energy-saving, preheat, pre-heat-rapid start, rapid start, instant start and "slim-line" linear models. HO protective lights are available for use in non-refrigerated and refrigerated areas. High-output fluorescent lamps for non-refrigerated areas are designed to withstand the highest temperatures. VHO lamps are available for non-refrigerated, refrigerated and freezer areas. U-shaped fluorescents are designed to provide nearly the same light output as linear straight lamps of twice their length. Black lights are designed to help unit staff identify contamination in food processing areas. Teflon-coated incandescent lamps are intended to be used anywhere a light fixture exposes a bulb or doesn't offer adequate protection.
Energy Source(s): Most protective lights consume anywhere from 6 watts to 185 watts and require a 120-volt to 130-volt energy source.
Manufacturing Method: Protective lights' plastic coating captures glass, mercury or phosphors should lamps break. Teflon coating offers longevity and high performance at temperatures of up to 500°F., as well as resistance to thermal shocks and chemical contamination.
Standard Features: All protective lighting should include a skin-tight protective coating that contains all glass, phosphors and mercury, protecting a surrounding work area should a light shatter or break. HO fluorescent lamps designed for use in non-refrigerated areas typically feature a Teflon coating over a lamp's hot ends for ease of handling and a plastic coating over the entire length of a lamp for protective strength.
New Features/Technology/Options: New technology in fluorescent, shatterproof bulbs allows for much lower energy consumption, superior lumen maintenance and improved color rendering. Typically, metal halide lamps lose at least 40% of light output over their lifespan, whereas new high output (HO) lamps maintain 95% of original light output during their rated lifespan. Smaller, compact HO bulbs are also now available.
Key Kitchen Applications: Protective lighting is most applicable in freezers, refrigerators, prep areas, dining rooms and insect light traps in operations including restaurants, supermarkets, C-stores, "salad-toss" bars, schools, daycare facilities and meat-packing plants.
Sales Guidelines: While protective lighting is required in most prep/production areas, salespeople should inform their customers that a broken bulb always presents an injury risk, and, hence, litigation risks, to workers and customers, so protective lights should be installed throughout an operation. Additionally, while some operators may be tempted to use standard bulbs as replacements, DSRs should remind them that glass from a shattered light can necessitate that hundreds of dollars worth of food be discarded.
Maintenance Requirements: The suggested maintenance on all protective lighting is called group relamping, which is the replacement of all lamps after they have been in service for 70% of their use-life (average lifespan ranges from six to 3,000 hours). Replacing lamps before they burn out eliminates flickering and protects ballasts and other system components.
Food Safety & Sanitation Essentials: While black lights are designed to identify food contamination in processing areas, all protective lighting is designed so that unit staff never have to touch or be exposed to bare glass and to ensure foods cannot be contaminated by broken glass or other lighting components. The FDA Food Code Chapter 6, Section 202.11 states, "Shielding of light bulbs helps prevent breakage. Light bulbs that are shielded, coated or otherwise shatter-resistant are necessary to protect exposed food, clean equipment, utensils and linens, and unwrapped single-service and single-use articles from glass fragments should the bulb break."
Warewashers
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Types: Warewasher models include undercounter, door-type, flight-type or rackless-conveyor, rack conveyor-type dishmachines, upright conveyors and circular conveyor-type units. There are also warewashers that are designed to clean specific types of ware, such as glasses, pots, pans and utensils.
Capacities/Footprints: Warewashers are distinguished by the racks or glasses they can wash per hour. Undercounter dishwashers and door-type machines generally wash 21 to 55 racks per hour, while a glasswasher can wash 1,000 to 2,000 glasses per hour. Flight-type or rackless-conveyor dishmachines can wash more than 21,000 dishes per hour at an NSF-rated belt speed of 13.69/min. Single-tank and multiple-tank rack conveyors can be adjusted to wash up to 288 racks or 28,000 dishes per hour at a maximum conveyor speed of 10.99/min. Pot, pan and utensil washing machines can have a six- to 60-pan capacity. Circular conveyors can wash a maximum of 122 to 320 racks per hour at a conveyor speed of 3.49 to 9.09/min.
Undercounter dishwashers and door-type machines are the most compact, function best and are best-suited for use in smaller kitchens. Undercounter dishwashers usually do not exceed 230 wide 3 250 deep 3 530 high in overall dimensions, though most units measure approximately 330 in height. Door-type machines are also designed to conserve space, while providing high production in small dishroom areas. Door-type machines are typically approximately 260 wide 3 250 deep 3 920 high. Glasswashers can be as large as 720 wide 3 220 deep 3 380 high. Upright conveyor systems offer high-volume operators continuous dish-rack or direct-drive loading. Conveyor systems' largest section can be 49 wide 3 79 to 109 high.
Energy Source(s): The majority of warewashing machines operate on electric power levels ranging from 115V for smaller machines to 460V for larger units. Some warewashers offer the option of either electric, steam or gas water-heating systems, while others are available only with single-source gas-heating systems.
Standard Features: Undercounter dishmachines can feature built-in electric booster heaters, "air glide" door designs, fully automatic wash and rinse cycles, minimal aisle restriction when a door is open, self-sealing gasketless doors, upper and lower wash and rinse spray systems, and flexible hoses designed to make installation easier.
Space-saving door-type machines typically feature automatic tank fills, door-activated drains, front-mounted tanks for easier cleaning, built-in 40°F. or 70°F. rise booster heaters, straight-through or corner-model configuration, top-mounted controls, interchangeable upper and lower spray arms, 1-hp pump motors and detergent/chemical connection provisions.
Glasswashers generally feature a built-in dispensing system for detergent, rinse additives and sanitizers, and an automatic conveyor drive system. These single-switch machines feature separate wash and rinse temperature gauges, powerful wash pump motors and a 100% fresh-water rinse.
Flight-type or rackless warewashing units usually feature dual fresh-water rinse functions. The systems' large removable panels and inclined, self-cleaning tanks are designed to simplify daily maintenance. Designed with energy efficiency in mind, these systems' double-wall insulation reduces noise and retains heat. Units' wash-arm designs maximize pressure, which can result in superior soil removal.
Rack conveyors most often feature automatic tank refill, leak-proof doors, rinse-saver devices, 2-hp wash pumps, a door-activated drain closure, removable spray arms, convenient top-mounted controls and interchangeable spray arms.
Pot, pan and utensil washers typically feature a maintenance-free hub system, separate wash and rinse tanks, self-contained booster heaters, adjustable wash and rinse cycles with a selector switch, high-velocity spray nozzles designed for fast stripping action, an external pre-rinse wash-down hose, automatic fill functions on utensil models, heavy-duty racking systems, electric, steam or gas heating systems and, sometimes, a loading ramp or pit grid for rack washers.
Upright conveyor systems usually feature extra-wide conveyors for high-capacity operations. Some standard features include idle pump shut-offs, rinse savers, top-mounted control consoles, push-button start-stop controls on the load end, conveyor shut-off shelves on the unload end, common drains and electric connections, chemical dispensing connection provisions and water regulating valves. Upright conveyor systems also usually offer a choice of tank heat: electric, steam coils or direct steam injectors. Some units feature access doors on both sides of the hood and clean-out doors on the end and sides of a machine for easier access.
Here's the continuation of the Product Knowledge Guide section on Warewashers available in the September 2004 magazine.
New Features/Technology/Options: Newly developed spray nozzles in conveyor-type warewashers can cut the amount of water required by 50%, thereby providing savings by reducing the amount of energy required to heat water and cutting rinse agent/chemical use. Rather than a standard fan spray nozzle, the new nozzle relies on high and low pressure, causing the water spray to oscillate in an S-pattern. The result intended is more uniform coverage and a more forceful stream of water.
Sales Guidelines: Since different wares have different washing requirements, DSRs must know what their customers intend to wash in order to specify the correct unit.
Many local codes require warewashers' water temperatures reach a minimum of between 160°F. and 180°F. Using a building's water heater to reach such temperatures can result in patrons being burned when they wash their hands. DSRs should, therefore, encourage operators to add water temperature-boosting devices to their warewashers.
Maintenance Requirements: To maintain the performance of a warewashing machine, most manufacturers suggest that commercial-grade detergents be used and water temperature and pressure not exceed specifications.
Food Safety & Sanitation Essentials: Warewashing machines are designed to eliminate any contamination of cooking, eating and drinking utensils by effectively sanitizing wares at high water temperatures.
Sinks
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Types: The multiple types of sinks now available for foodservice operations are classified by function. NSF-rated sinks are required to be manufactured with radiused seams, coved corners and integrally welded drainboards for most effective sanitation. Non-NSF units typically have unground welds and detachable drainboards.
Capacities/Footprints: Local Health codes govern the size of kitchen (skullery) sinks, including the number and size of bowls, water levels, backsplash heights and drainboard sizes. Minimum pot sink bowls should be 200 3 200 with at least a 120 water level and should have at least three compartments (wash-rinse-sanitize) and two drainboards. Customized sink units can include up to four compartments, a disposer cone, pot washer, racks and shelves, a side splash and drain trough.
Standard Features: Sinks typically are made from stainless steel for durability and easy cleaning. The steel can be type 430, which has a 16% chrome content, or the thicker, more durable type 304 that contains 8% nickel. Sink components include a backsplash, compartments or bowls, a drainboard, front roll rim, legs and fittings. Bowls may be fabricated or deep-drawn. In some instances, sinks are mounted on a wall, but they are generally supported by legs fitted with adjustable bullet feet for a level setting. Faucets, drains and grease traps complete a sink unit, which must be welded. A gooseneck, swiveling faucet is required to reach each compartment of a sink, and airators and stream regulators save water.
New Features/Technology: Specialty handwashing sinks are now available with an anti-microbial epoxy coating to retard the growth of bacteria, mold and mildew that may cause stains, odors and degradation of wash surfaces. Some handwashing sinks are now available with automatic tracking of employee hand sanitation for HACCP-compliance documentation, as well as "hands free" water and soap dispensing. New developments in pump technologies have renewed interest in semi-automatic pot washing sinks, which use high-powered jets of water to clean items such as pots and pans, rotisserie spits, utensils and even hood filters and oven parts. In these sinks, water is pumped through at a rate of 300 to 400 gals. per minute.
Sales Guidelines: Since there are so many different sinks available for different applications, the first job of a DSR is to determine what an operator customer plans to use a sink for and to recommend the best model based upon this knowledge. DSRs would be well-served to recommend sinks that have useful higher-end features, such as easy-to-clean corners and seams, designs that limit splashing and raw materials infused with anti-microbial agents.
Maintenance: Frequent cleaning and sanitizing of sinks is necessary and preventive care to avoid rust and corrosion is advised. Only mild soap and water or non-abrasive cleansers should be used to clean stainless-steel sinks, which should then be rinsed and wiped dry. Abrasive cleansers will scratch and dull surfaces. Food Safety & Sanitation Essentials: Handwashing sinks help to comply with HACCP guidelines in foodservice kitchens, as most local Health codes do not allow employees to wash their hands in a dish sink. Handwashing sinks should be readily accessible and very visible, and employees should be educated as to proper handwashing techniques. Benchmarks to consider are: One hand sink for every five employees; one hand sink for every 300-sq.-ft. of facility space; one hand sink for each prep and cooking area.
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