Prevention is better than Cure (and a big engineers bill!)

Take a few minutes to read the following advice and save yourself some money.

 

WAREWASHING

Regular cleaning will improve the life of pumps and help provide the best quality wash by keeping the machine clear of waste products. Clean out the strainers regularly, at least twice a day. Check the strainers are not damaged and that they are fitted correctly so as to not allow waste residue/utensils to pass through which will damage pumps and possibly cause blockages, especially in energy recovery devices. Replace immediately if damage is evident. Cutlery in wash pumps is one of the major causes of failure.

The larger the dishwasher, the greater the need for good staff management and training. Check that doors are put back in position correctly before making a breakdown call. Always ensure curtains are fitted and in the correct place, this will reduce the heat loss and help to maintain the correct temperature in each section.

Operating temperatures - if the machine is displaying temperatures which are different from the manufacturer's recommendation, have the machine checked urgently to avoid hygiene risks. It is vital that the final rinse temperature maintains 82 °C for proper machine performance. The temperature of the wash water is also important, too low a temperature will cause excessive detergent foaming, generally the water needs to be between 55 & 65 °C. Always keep hoods and doors closed when machines are not in use.

If the machine cycle is longer than usual, don't assume there is a problem with the machine, outside influences can affect machine performance e.g. low temperature of incoming water in winter, room temperature and the use of machine outside its operating parameters.

When the engineer calls for a breakdown or routine maintenance visit, do you really want to pay them for clearing access to the machine or cleaning gunk and dirt away to get inside? It is simply a waste of our time and your money to have an engineer move a massive pile of dirty plates before he can take a look inside the machine or clear debris from filters or wash arms, which should be done in routine cleaning.

If, after all that cleaning, the dishwasher still has a cloudy off-white coating inside, that is limescale building up which will constrict pipework, make the pumps work harder and damage heating elements. Check your water softener is working properly. It should be easily accessible to allow regular top-ups with salt, which staff can forget to do. If it seems to be working, it may need adjusting to regenerate more often.

FRYERS

CLEANING

Oil can build up around control dials, making them more difficult to move and risking the dial breaking. Clean around the dial as part of your regular routine; if the dial pulls off, clean behind and replace the dial. Ensure that ventilation fitted above the fryer is clean and operational.

OIL CHECKS

Fryers are the cause of many personal injury accidents and fire hazards. Most important, if oil starts to smoke at normal temperature settings, the thermostat may be faulty, so get it checked before it all catches fire. Also, if the oil becomes cloudy when hot, or very dark, change it. Filtering the oil every day is a great habit to get into - most of the running cost of a fryer is in oil, so maximizing economy and cooking quality makes sense. Before draining the oil, ensure the fryer is switched off long enough for the oil to cool to 60°C or lower. Don't leave it switched on at low temperature, or the oil may overheat when the level drops below the thermostat probe.

THERMOSTATS

If you notice the fryer is not cooking normally, the thermostat probe may be out of calibration leading to inefficient cooking. Thermostats naturally 'wander' from their pre-sets over time, so over the life of a fryer, having them re-calibrated several times to ensure maximum energy efficiency and operating safety is not uncommon. A common cause of damage to thermostats is when refitting electric elements after cleaning, so lower them carefully into position so to not damage the thermostat probes.

NEW FRYERS NOT WORKING

As fryers become more and more electrically sophisticated new equipment that refuses to work is not uncommon. The fryers could have been tripped during installation as the power was switched off/on; or they were tested and left on without any oil. It will take an engineer around 10 minutes to re-set the fryers. If the thermostat trips out, you may be able to reset it, but don't do that more than once. Call a service engineer to check it.

FILTERING

Fryers with internal filtering systems rely on the filters to stop food debris from clogging the pump. Make sure you know how to remove and clean the filters before filtering the oil.

GAS FRYERS

Gas fryers must be checked regularly for proper combustion to ensure that CO2 levels are within acceptable tolerances. Thermostats must be checked periodically to ensure they continue to function correctly.

Electrical cables need to be inspected to ensure there are no damage or earthing faults. A qualified service engineer can carry out these checks for you.

BEVERAGE MACHINES

Machines plugged into a 13 amp socket will need to be PAT tested, along with all other electric portable appliances.

Pressure boilers need a pressure vessel inspection annually by your Insurance Company. To save cost, arrange for your service engineer to service the boiler at the same time.

Hard water scale causes most maintenance problems in boilers and beverage machines. Always use a water treatment device recommended by the manufacturer.

If a filter cartridge is fitted, it will need regular replacement. Make sure your supplier advises you when this is likely to be needed.

Plan to have the boiler inspected and descaled regularly. A hot tap boiler won't pour properly when scale hardens around the spout, which could cause scalding.

Descalant powders and liquids can be hazardous, and are covered by COSHH regulations. Make sure a competent person does the descaling, and flushes it thoroughly before resuming service.

Coffee grounds will find their way into every crevice, so make sure that coffee machines are cleaned rigorously, before a service engineer has to take it all apart to clean.

COOKING RANGES

The correct flame colour for natural gas burners is blue, with no yellow. If it burns yellow, you are releasing unburnt gas into the kitchen, which will cause breathing problems for staff.

An extract canopy must cover all gas equipment, and be capable of extracting all fumes. Test it yourself with a candle flame which should pull towards the hood when it's on. Ask your service engineer to do a smoke test if you are unsure.

The burner jets on gas boiling tops and ovens often get blocked by spillage. Clean the burners every day to keep them clear.

When cleaning the burners, take care not to displace or damage the thermocouple which senses the gas flame. Make sure that gas burner heads are replaced exactly in position after cleaning.

To clean the burners, use a damp cloth with hot soapy water, a soft brush, and a lint-free dry cloth. Avoid caustic or acid cleaners unless recommended by the range manufacturer. These can literally 'eat' burner rings or fittings.

When cleaning electric ovens, make sure they are switched off at the isolator before using cleaning fluids around electrical components. Make sure everything is dry before switching on again. Some gas ranges also have electronic ignition, so they should also be isolated from the electric supply.

Occasionally, remove the plates from solid top ranges to clean underneath. These are very heavy, and must be cold before removing them. Put them back in the same positions so that they fit together again.

If one or more gas tap knobs on your cooking range become exceptionally hot, there may be heat escaping from the oven underneath. This means that the door seal needs replacing.

Gas taps get stiff after a time because the grease has dried out, especially if they are above an oven. Have your service engineer re-grease them before the control knob breaks, or the whole gas tap seizes up and has to be replaced.

Avoid standing on drop down oven doors which will bend the hinge mechanism.

All newly installed and refurbished kitchens must have a safety interlock which turns off the gas to the cooking equipment if the ventilation hood isn't working.

COOKWARE

Cutlery and cooking utensils are the main cause of jammed dishwasher pumps and waste disposers. Make sure that all cutlery and utensils are removed before plates are scraped. Place cutlery and cooking utensils in the correct basket before putting them in a dishwasher.

Plastic cutlery can easily be drawn into dishwasher pumps and then block the wash arm jets. So if you do wash them in a dishwasher, take extra care.

Spillage from pans which boil over is the biggest cause of blocked jets on gas cooking ranges. Use a pan that will be big enough to avoid boiling over.

Most microwave ovens will be damaged if using a metal pan or container. Use only microwave safe containers.

High-speed microwave combi-ovens can use foil containers, but it’s best to check with the manufacturer before making your choice.

Aluminium containers should not be washed in a dishwasher, the detergents used will discolour the aluminium and make it go black. Use a hand held pot scrubber or soaking sink.

Stacking pans and containers on top of one another in a dishwasher will not get them all clean. Stack the pans singly and facing downwards for the best results.

To avoid accidents, pan lids should be stored separately and not stacked on shelves above shoulder height.

Large granule dishwashers, which fire granules at baked on foodstuffs, need to be carefully loaded to ensure everything is cleaned. Pots and pans should face the wash arms, and not allow water to be trapped in the containers when unloading.

Ensure your dishwasher uses the correct detergent for each purpose - pans which are hand washed must use hand wash detergent. Do not use dishwasher detergent which can cause irritation if it comes into contact with skin.

SERVERIES

Regularly check the trolley temperature read-out against your hand-held reader. If it's not the same (or almost the same), don't use the trolley again until a service engineer has checked the heating and calibration. When it's hot in the summer, leave the display case operating temperature at normal - don't turn it down. It will ice up the evaporator, and cause it to go over temperature.

Refrigerated servery counters may not be designed for storing food overnight. After service, move the chilled products to overnight storage and switch the servery off, so it can defrost.

Use only food-approved lamps in your heated display counter. Keep a spare one handy so you can get it replaced quickly when you need to.

Open-front display cases may struggle to maintain temperature if the curtains are not pulled down between service and overnight.

Most trolleys have bumpers, but these are to protect them (and your premises) from damage, and not to encourage rough handling. Most damage to trolleys results from careless use such as crashing the castors over rough ground, and bashing into walls.

Remember to release the brakes before towing otherwise the castors will flatten on one side. Damaged castors are a safety hazard, so must be replaced as soon as possible.

If you see damage to the cable on a heated or refrigerated trolley, don't plug it in - have an electrician check the cable and gland.

MICROWAVES

A little known fact is that magnetrons deteriorate over time, some makes more than others. If you use a set programme or button for reheating a steak and kidney pie, for example, you might find after five years this is no longer cooking properly and you may need to adjust programme parameters.

Electrical safety checks and emissions testing: The EHO can ask when your microwave was last tested. There is nothing mandatory about this but to prove 'due diligence' it should be done as part of your regular service arrangements or at least annually, especially for heavily used ovens. Domestic versus commercial: When buying a new oven, use a reputable catering supplier and check that it will stand up to the pressure/number of meals throughput. Domestic ovens overheat and will not stand up to the pressure of a busy session.

Clean spillages immediately to prevent burning, increased energy usage and risk of fire. Pay special attention to bottom door hinges (if relevant) and door edges and recesses where food can build up and prevent the door closing flush with the microwave body, increasing the potential for microwave leakage.

A common problem with bottom hinged doors is that people place heavy weights on them/use them as an extra shelf for which they are not designed.

Combination microwaves can weigh 45kg+! If fitted with a grill, it will have the magnetron mounted in the bottom, making it more susceptible to problems with burnt on dirt. They are harder to keep clean because of the combination of grill, convection and microwave; there is more fat splattering inside. These units should be kept sparkling clean with spillages cleaned up immediately and no build up of dirt or food allowed.

Most commercial microwaves can weigh 30-50 kg which is a real issue when you need to move it to clean under, so two people will be required to lift it. Also make sure the unit is unplugged or that you have enough spare flex from the hard connection to move it safely. Some ovens have 2 metres of cable, make sure this will not get snagged or damaged by other items.

Never place a microwave near a fryer; it will suck in greasy air from the fryer which will cause cleaning and operational issues.

If a user removable filter is fitted over the air intake, it should be cleaned as per user instructions on a regular basis.

Do not block air outlets on top or behind ovens .

COOK-CHILL

To ensure that core food temperatures are reached in the cooking and chilling processes, it is usual to use a food probe which displays the core temperature on the oven or chiller readout. Because food probes are easily damaged, it's sensible to keep a spare probe available for a service engineer to fit without delay.

Whatever the size of your cook/chill operation, maintaining the correct temperature throughout the cook chill process is crucial, so it's vital that the temperature readout on every piece of equipment is working correctly. This means regularly checking it against an independent temperature device. A service engineer will always carry one if you are in any doubt about the correct temperature reading.

There should be no unnecessary delays between each process, so having a regular check of prime cooking equipment, blast chillers, sealing machines, mobile trolleys and regeneration ovens is vital. Gas-fired equipment must be checked at least once annually for safe operation, and refrigeration equipment needs at least one condenser clean each year.

Electrical safety is also crucial, particularly where equipment is being moved about. Check cables and plugs for signs of wear or damage every day. An electrical check to ensure that equipment is properly earthed and insulated is essential at least once a year.

When using a number of mobile trolleys for distribution, each trolley must be checked to ensure it complies with temperature guidelines, and can retain the heat or chilled temperature until service. If door seals are damaged, or control boards are faulty, take the trolley out of service until it's repaired. Check that the doors close properly each time before loading the trolley with food.

Mobile trolleys can be dangerous when being pushed or towed. So every time they come back to base, check the wheels and towing mechanisms for signs of damage. If a trolley has been bumped against a wall, it's better to have an engineer check it before it's used again.

DISHWASHERS

SAVE WATER

A dishwashing operation in a typical restaurant could be consuming two-thirds of all the water used by that restaurant. A common fault such as a poorly fitting drain seal can allow water to drain away during operation, therefore needing more heated water to maintain the washing cycle. It follows that the embedded energy costs, as designed by the manufacturer, will only be achieved if the equipment is regularly maintained and serviced.

TEMPERATURES

The machine operating temperature is crucial to the effectiveness of its washing and rinsing. The detergent works best at pre-set wash temperatures and rinsing at 85 °C is necessary to ensure a hygienic finish. Check your temperatures at the end of a busy session, and if they are not as stated in the manufacturers handbook, phone for a service engineer.

WATER QUALITY

The quality of water supplied to your dishwasher is important and if you have a water softener fitted (most caterers should), check that it is full of salt and that it is refilled regularly. It's generally cheaper than repairing damage caused by scale! Excessive limescale will also add to your energy costs. Only a few millimetres of scale can add more than 10% to your bills. A heating element which is thick with scale uses up to 50% more energy to reach working temperature. Hard water also requires more detergent, so keep the softener topped up.

PUMPS

Broken glass and cocktail sticks are the curse of glasswasher pumps. And it's not uncommon to find dishcloths and teaspoons that have found their way into a dishwasher pump. These repairs are not covered by manufacturers warranty, so make sure that the filters supplied inside the machine are in place and are not damaged. On flight-type and rack conveyor machines, it's easy to miss putting a filter back properly in place.

FILTERS

You'll get a better washing result and not have to clear the dishwashers filters so often when you take a moment to check that plates are being properly scraped of food waste when the dishwash operation is in full swing. If you have a pre-rinse sink or waste disposer, check that these are being used to clear food waste before putting them into the dishwasher. Excessive food waste will also clog the spray arms, and reduce the effectiveness of the detergent.

GRANULE WASHERS

If you're using a specialist granule washer, make sure that the granules are replaced regularly. As they become smaller, they become less effective against burnt on food deposits, and you'll end up having to put items through more than once.

FOOD PREPARATION

SAFETY

Safety guards and stops are there to protect the operator. They should not be used to stop the machine in normal operation! Do not allow staff to operate the safety guard to stop the machine to add ingredients or stir the contents etc. Always use the control panel to start and stop mixing machines. Some mixers, when stopped using the safety guard only, will restart without resetting the gears, starting to stir a heavy batch of dough in 4th gear will overload the motor which may burn out damage the gearbox or belt drive.

TOOLS

If you have mixers from different manufacturers, make sure you keep the tools separate. Damage may occur if they are fitted to the incorrect machine. Do not allow staff to place cutter blades on their edge as this will cause blunting. Tapping a mixer whip on the edge of the bowl will damage the wires, so use another method to remove the food mix from the whip ie., scrape with a spoon.

MOVING MIXERS

Mixers by their design are top heavy and should be lifted with care. A risk assessment must be carried prior any attempt to move mixers to ascertain whether the mixer can moved safely without use of lifting equipment. If the mixer is moved, use the correct lifting points and supported correctly. Do not, at any time, attempt to lift the mixer by means of the shaft or attachments.

POWER

If the unit fails to function ensure that it is plugged in securely and that isolator/switch is on, also make sure there is no damage to the power cable and/or plug. All power leads to machines should be checked regularly for wear or damage and replaced/reported as necessary. Portable appliances fitted with 13amp plugs should be checked for visible signs of damage to the mains cable and plug every time they are used.

SITING

Food mixers and processors can 'walk' under heavy load and become unstable. Equipment should be secured to the floor or work surface to avoid accidents.

LEAKAGE

If your food mixer has oil dripping down the attachment/planetary shaft or from the drip cup, an oil seal may have failed. Have it checked by a service engineer before possibly contaminating the food mix.

SLICERS

Slicers have a blade sharpening tool provided when new, this should be used regularly to maintain the slicer's performance. Make sure that the blade removal tool is used when taking the blade off for cleaning.

MINCERS

If your mince looks 'mushy' or is not coming out of the mincer properly, don't just tighten up the adjusting ring - renew the blade, plate, cylinder or worm before damaging the entire attachment.

FROZEN FOODS

Putting part-frozen products through a veg prep unit can damage the blades, so make sure everything is defrosted first.

STONES

Always check bags of potatoes for any stones before feeding them into peelers then chippers to avoid any damage.

REFRIGERATION

If you have a coldroom, look closely at the evaporator, that's where the cold air is blown from. If there is any ice on it, or around it, particularly at the back or sides, there's a problem. If the ice has formed a stalactite, there's a bigger problem. You'll need a fridge service engineer to examine the cause.

Look closely at the ice from your ice maker. If it is usually clear, but has become cloudy, you may need to have the icemaker descaled. If you have a water filter fitted (most caterers should), change it at least once a year, and before the summer is a good idea. If you have a removable filter, pull it out and wash it thoroughly.

On fridge and freezer cabinets, look closely through the condenser cover; this is the piece of stainless steel which has holes cut in it. If you can see lots of fluff or dirt covering the components, have it properly cleaned by a fridge service person. This will help stop the risk of overheating when it gets hotter.

Open each fridge and freezer door, and wash all round the door seal with warm, slightly soapy water, and a cloth. Don't use a knife! Check closely for splits or ill-fitting seals and replace if damaged. Split seals waste huge amounts of energy and you don't need that when kitchen temperatures soar.

Check the temperature readouts of all cabinets at the end of a long shift; these will show if a cabinet is recovering temperature properly when used heavily. If they are not recovering the correct operating temperature - and especially if your fridges or freezers haven't pulled down to temperature after working all night - call an engineer immediately.

With greater throughput in the summer, train your staff to stack the fridges and freezers properly. Do not stack boxes all round the evaporator, and don't fill a cabinet or bottle cooler so full that the air can't circulate. Remember to chill bottles first before putting them in a bottle cooler.

COMBI OVENS

REGULAR MAINTENANCE

Today's combis are built to exacting standards with clever self-diagnostic systems. And service engineers have been trained to download information from your combi, and upload the manufacturer's most recent software programmes. If you don't have your combi serviced regularly, you will be storing up trouble which can easily be prevented.

WATER TREATMENT

Fitting a water treatment filter or calcium treatment unit is the only way to ensure that the water in your combi is scale free - regardless of what you think the water softness in the area is like. Water treatment assures food grade standard of potable water, removing heavy metals, lead, copper, mercury etc., and chlorine as well as limescale.

MEATS

If you only ever roast meat in a combi, or use it mostly in convection mode, it will need to be cleaned more often to remove the build up of food soil and fats. For machines with a self cleaning option, run this cycle once a day. Running the machine on a steam cycle for an hour will help clean the cavity and flush the drain. The fat filters should be removed and cleaned to avoid any risk of fat residue catching fire.

PROBES

Shutting the meat probe in the door, or leaving the probe in a joint of meat when taking it out of the oven, will damage it. The probe must be put back in the holder every time after use.

DOORS

Always make sure that rack inserts are pushed fully home into the combi especially when using a roll-in trolley system. If the rack sticks out, it can shatter the glass when you shut the door.

SEALS

Periodically clean then lubricate the door seals with an approved silicone grease to prevent them sticking together. Make sure that the roll-in trolleys are properly lined up before pushing them into the oven and always replace the door seal when a split starts - it will only get worse!

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