Axis Purchasing – Inventory Control – Basics for Foodservice · PDF fileWarewashing – An In-Depth Analysis ... impact your bottom line and many other parts of your business

Axis Purchasing – Headquarters - (703) 310-7607

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2014

Axis Purchasing – An In-Depth Look at Warewashing

White Paper – An In-Depth Look at Warewashing

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Warewashing – An In-Depth Analysis November 2014

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Axis Purchasing Headquarters (703) 310-7607 www.axispurchasing.com

An In-Depth Look at Warewashing

Often overlooked and even more often misunderstood, foodservice warewashing is the method by

which dishes, glasses, flatware, pots and pans, etc. are cleaned by an automated or manual process that employs hot water, agitation and detergent. How you set up your warewashing system will greatly impact your bottom line and many other parts of your business.

A facility’s automated dish machine is often its most expensive piece of equipment and, ironically, usually operated by the least trained employees. Warewashing equipment costs many thousands of dollars to buy and install, and the process creates the biggest impact on a foodservice operation’s utility costs. In some cases, small foodservice operations employ a manual warewashing system that requires a small outlay, heavy labor costs and inconsistent results.

Many operators miscalculate the costs of maintaining an efficient warewashing system because they focus on chemical costs, which are just a portion of the total outlay. As warewashing runs all day every day, there is in fact, nothing more essential to monitor and understand when determining one’s foodservice operating budget.

The options regarding the size and scope of your warewashing system vary depending upon the size, make-up and menu of your operation. Factors include architecture, flow, water quality, manual or automated systems, environmental concerns, plumbing, electrical and local codes.

Ultimately, the goal of warewashing should match both your budgetary constraints and your corporate philosophy regarding efficiency, environmental practices and human relations. The system you choose should provide you with spotless results the first time, every time.



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The ABC’s of Warewashing

It is necessary to understand the essentials of an automated warewashing system to ensure you choose the right one for your operation. Choosing the right system can reduce labor and utility costs while producing excellent and consistent cleanliness.

System Ratings Dishwasher ratings are based on the number of full dish racks washed per hour. The machine’s rating is important to understand in order to select the right type and size dishwasher that fits your facility. The standard dish rack is 20” × 20” and can hold roughly 18 dinner plates or 25 to 36 glasses. Capacity will vary based on the size of the items washed including bowls, flatware, etc.

Pumps and Motors The pump and motor combine to provide the right amount of water volume and pressure in compliance with regulatory codes and proper cleaning. The pump is measured by its capacity in gallons per minute (GPM). The motor is rated by its horsepower (HP).

Heating Equipment Water heaters are an essential part of automatic warewashers as they monitor and maintain the correct water temperature in the unit’s tank. They run on electricity, steam or gas and produce a water temperature of 160 degrees to ensure sanitation. Booster heaters bring the temperature up to 180 degrees or more for the final sanitizing rinse cycle.

Rinsing In order to rinse properly and abide by National Sanitation Foundation (NSF) standards, the water pressure for the rinse cycle must be between 15 to 25 PSI. A solenoid controls the final cycle while a pressure gauge measures water pressure and a reducing valve monitors the pressure.

Sanitation Compliance Look for an NSF certification on the equipment you buy. A certified machine will prevent bacteria build-up by removing excess food and other residue. The equipment should comply with FDA Hazard and HACCP rules. All parts of the machine must be checked and certified.

Important Consideration There are a variety of factors to consider when selecting a warewashing system including the effect on utilities, whether to go with a manual or automated system, how to offset poor water quality, the environmental impact and chemical costs.



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Washing technology and energy efficiency

Commercial kitchens are not only energy intensive, they are water intensive.

Perhaps you are working with a restaurant chain, big hospital kitchen or a university cafeteria. These operations employ heavy-duty appliances for cleaning large amounts of cookware, dishware, silverware and glassware.

Since these energy- and water-intensive, appliances are frequently used over long hours, businesses and institutions can realize substantial savings by choosing high-efficiency models.

Washing, or sanitation, accounts for 18 percent of a commercial kitchen’s energy costs.

A. Utilities

In warewashing, there are two main cost drivers:

1. Water consumption (cost of water and sewage)

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Different machines use water at anywhere from a high of 2+ gallons per cycle to a little less than a gallon per cycle (.93/gallon).

Electricity for temperature control

o All dishwashers heat water to some degree. Low temper-ature machines bring it up to 140 degrees and require an additional chemical sanitizer. High temperaturemachines rise to 180+ degrees but do not require a chemical sanitizer in rinse. High temperature machineshave additional heaters and use more electricity than low temperature types.

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Hot water is the most necessary component of a quality system. For maximum detergent efficiency, themachine needs 120 – 145 degrees combined with detergent and wash agitation to clean your dishes.

2. Electricity which powers the machine operations andwater temperature (dictated by machine type)

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For every gallon of water consumed operations also incur a charge for a gallon of wastewater in sewage.

Water consumption

Electricity for machine operations

Power is consumed to run the pumps, conveyors and exhaust fans.

Energy is consumed for vented exhaust will increase the cost to air-conditioned make-up air. The air thatreplaces exhaust fans venting over the machines.



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B. Areas to Control

Maximize Utilization – Wash full loads.

Run Time – Turn off machine during periods when not in use.

Rewash – Use proper detergent to maximize clean performance the first pass.

C. Water Quality

The harder the water, the worse your warewashing performance. If you do not have an actionplan to offset hard water, it will result in spots and films on dishes and glassware. Spottydishware will adversely affect your restaurant’s image. Hard water can play havoc and hurt thelife span and maintenance costs of the dish machine. Scale build-up, clogged jets, increasedbreakdown poor performance, etc. can shorten machine lifespan.

What can you do?

Affect the chemistry by using a detergent and rinse aid specifically designed for hard water.

Install cartridge filters in line to the dish machine feed, or add a water softener system to thewater main coming in to the facility.



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D. Chemical Costs

The use of chemicals is determined by the number of products required; sanitizer, rinse aid,presoak, and dilution ratios.

Chemicals costs are measured in per rack cost to wash (all chemicals, various doses/dilutions). An aggressive program costs between 5-7 cents per rack.

For lowest cost, opt for super concentrated chemicals that have a long dilution and a low in-usecost.

Chemical mix also drives results in hard water.

Pre-soak. If you do not use it, soil will stay on cutlery. Some operators cut corners and do notuse it. In addition, a proper pre-rinse procedure is a key performance issue. If you try to washnon-rinsed dishes in the machine, soil baked on the dishes may require the time and cost to re-wash.

E. Titration

Titration is the concentration of warewashing chemicals in solution.

It needs to be accurate, consistent, and measured.

Titration affects both performance and cost; use too much soap and therinse aid will not work; too little sanitizer and you may be out of compliancewith the local health department.

Remember to check the dosing equipment and nozzles on a regular basis.

F. Environmental Impact

AVFOGS (Animal, Vegetable, Fats, Oils, Grease and Solids) are part ofevery foodservice operation’s washing system. Studies show that 93percent of AVFOGS end up in the drainage system.

Clogged pipelines can overflow into sewer lines and storm drains whichlead to water sources like streams, ponds, lakes, aquifers and groundwater. The effects of thisrunoff can contaminate the ecology and wildlife in your community.

Many operators rely on grease traps to slow or capture the grease from their operation. Theywork in the facility but you can also install an interceptor to hold AVFOGS until a recyclingcompany can remove. Today, there are companies that will pay operators for their grease foruse as an alternative fuel. There are also environmentally sound liquid separators that work withyour system to help eliminate this waste.



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G. Manual Warewashing

For small operations, manual warewashing can be an efficient and cost-saving alternative to automated systems. This method of hand washing meets the minimum sanitary requirements as well as the budgetary needs of a small foodservice business.

All that is required is a three-compartment sink – for washing, rinsing and sanitizing. In addition, the minimum temperatures are much less than with an automated system: 110 degrees for washing, 75 – 120 degrees for rinsing and chemical sanitizing.

Chlorine, Iodine, and Quaternary Ammonium (or QUATS) are commonly used chemicals to sanitize dishware. The amount of chemical concentration required will vary by chemical and/or local regulations.

The advantages of manual warewashing include its low cost, investment, maintenance and hot water usage.

However, it is labor intensive and therefore can be inconsistent and slow. A consistent water temperature in each compartment is required but difficult to maintain since you have to drain and refill each compartment and add detergent and/or sanitizing chemical. At the peak business hours, washing, rinsing and drying wares can create a bottleneck that affects service.

Manual warewashing usually includes chemical dispensing systems. Wall mounted pumps are the least expensive method. There are also systems that attach to the spout to siphon detergent or sanitizer into the sink.

Because washing dishes manually is controlled by human hands, the use of detergents and sanitizers is hard to control and can reduce overall efficiency while raising costs.

H. Automated Warewashing

There are many reasons why automated warewashing is the preferred method for foodservice operators. These systems can be tailored to fit the physical make-up of your facility because they come in a variety of sizes and configurations.

Automated systems offer labor savings (employees who wash dishware can perform other tasks during off-peak hours); quick turnaround, better flow and greater consistency and performance. However, such systems, which include either high or low temperature machinery, have higher initial costs and higher maintenance costs.



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The high temperature machines are usually preferred to the low temperature machines that employ chemical sanitizing to offset their temperature difference. For facilities that cannot provide enough heat for the high temperature systems, a hot water booster is required and helps raise the temperature to at least 180 degrees. Some systems come with temperature assurance systems to raise the final temperature to 180 degrees in the final rinse phase.

The beauty of a high temperature machine is that the dishes are so hot; the water evaporates at the end of the cycle and thus can be removed and stacked quickly.

With low temperature machines, there is the added cost of chemicals and the use of racks to allow drying time. This system also requires more space for the racks.

Equipment

In order to select the proper equipment for your automated warewashing system, you must consider many factors. Work with an architect, consultant, in-house engineering/maintenance person or dealer to make sure to consider all of the key factors as a way to head off any potential problems and determine all of the costs.

Asking the right questions is the key to proper installation. What is the system’s capacity for growth? How will it adapt to menu changes? What are the most important considerations for proper equipment choice?

Among the things to consider is the size of your operation, the menu, physical space and flow, electrical and plumbing capacity, venting and health/city code compliance.

Remember, too, that all automated warewashing requires enough hot water to meet NSF requirements for efficient cleaning; detergent is necessary to create the chemical action to remove food particles; and that there must be enough water pressure and volume to ensure the cleanliness and meet health standards.

Automated systems include a detergent tank, heating system, electrical system, rinse system, a hood for wash and rinse and pump and pipe system to spray the detergent.

Selecting your equipment:

Undercounter

Undercounter washers work best in confined spaces and with smaller amounts of wares. They are compact, efficient and reliable much like a home dishwasher.



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Selecting your equipment (cont.):

Door-Type Machines

Usually meets the standards for operations serving 50 to 100 people per meal and can wash 800 to 1350 dishes per hour. These machines offer energy savings via their low temperature, chemical sanitizing systems and include timed wash and rinse cycles and sliding doors for easy access.

Rack Conveyor Washers

These large machines can service over 4,500 dishes per hour and require the highest expenditure to install and maintain. The dish rack moves through the wash and rinse cycles at standardized rates.

Pot, Pan and Utensil Washers

For the big jobs and bulky ware, these machines have bigger clearance and higher power. High pressure and hot water work together to effectively sanitize all types of wares, pans and utensils. Jet sprays create enough pressure to remove backed on food and grease.

Maintenance

Much like your car or any other expensive item, you should adhere to the manufacturer’s guidelines for maintenance and care of your automated warewashing machine.

If not properly maintained, your machine could suffer from overuse or underuse of chemicals and utilities, break ahead of time, have poor performance and can even create health department violations.

You want your machine to run at peak efficiency or you could affect all or some of these areas:



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1. Water consumption and usage

2. Electrical

3. Worker safety

4. End results – unhappy customers and rewashes

Often times, people treat their machine like a garbage disposal. The worker may not pre-scrape or soak the dishes and pots well enough leaving unwanted food particles that can clog the machine. In a bar glass washer, garbage that is not wiped clean can really damage the motor and bearings. The trap is just not good enough to get all of the food. Even small items like toothpicks and fruit rinds can be very damaging.

The recommended maintenance for a dish machine is at least once per month by the company who sold you the machine. Some operations, like hotels or casinos that have non-stop business, are on a once a week schedule. Maintenance should be tied to the volume of business in your operation. You want to be on a preventative maintenance program.

Maintenance checklists include more than 30 different items and services, including:

Jets

Wash valves

The heating elements

Chemical used properly, etc.

Motor

OSHA violations

Timers

Pumps

Rinse arms

Cycle temps (wash, rinse and sanitizing)

Always make sure the machine runs according to its specifications. If not, you leave yourself open for negative consequences. Poor maintenance can lead to blown pump motors or cause other major problems that could be very costly. An ounce of prevention is worth a pound of pain.

Hygiene

The health department will regulate how the dishes are sanitized in the final phase. A dish machine should always sanitize dishes, cutlery, pots, pans, etc.

A low-temp machine uses chemicals to sanitize; and if the jets clog or if machine does not pull theright amount of chemicals, then the requirement for the proper titration, measured in parts per million, will not meet regulation, so dishes are not sanitized.



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On the other side, if you have a high temperature system and the heaters are not working properly, then you will have sanitation issues. The final temperature has to be 180 degrees or hotter. That is the reason you need regular checkups to remain in compliance with health codes.

Own or Lease?

Three ways to get a machine:

1. Purchase the machine outright.

2. Rent – Companies offer a monthly rate that some operations preferbecause it provides an easy way to get a machine or to upgrade if you grow.

3. Lease – In this case, a contract for fixed term is executed. Leasing is

an alternative form of financing. There are often options for termination allowing you to walk away or keep the existing machine for a small buyout.

The majority of foodservice operators lease unless they need a customized machine. Most foodservice operators generally lease or rent in order to reduce the initial cash outlay.

A chemical program is a straight acquisition in which you simply purchase a case of chemicals and

pay for it like any other product.

Per rack payments is another option. In this scenario, operators are charged for chemicals based on the number of racks of dishes run during a certain time period. Machines include a counter that monitors rack usage and charged based on number of racks used.

Cost per cover or cost per guest is another model of “pricing” a ware wash chemical program. Vendor and operator agree on the metric, and the accompanying cost factor. The operator provides the verifiable figure and the vendor calculates the cost. Usually programs like this are reconciled against what the operator spent in chemical for the preceding month. Vendor may owe a credit if programs costs are higher than negotiated.

Those programs tend to be challenging because there is often a minimum hidden cost. It gives the chemical company an incentive to reward that behavior. However, this can work adversely because people use too many dishes per rack to keep the number of racks at a minimum. It can affect your quality of the wash and actually reward bad behaviors.

Pricing options:



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Other Factors

When choosing and installing a warewashing system pay special attention to detergent usage, venting and foaming. In order to control costs yet still have the most effective detergent use, you must carefully monitor your detergent. Be careful not to waste detergent and to use with the proper water temperature. Even the amount of food left on dishes, utensils and pots and pans can affect how well your detergent works. The type of detergent you use should be determined by how hard the water is so as not to create “liming” in the dishwasher.

Proper venting allows for a better drying process and prevents the accumulation of moisture in the machine. Certain machines, like door-types, include a draft hood that captures unwanted moisture. Other machines have duct openings and risers to assist in venting. (Note: the dishwashing area should also be well-ventilated so that the workspace is not to hot or wet for your workers.)

Foaming occurs with certain products like eggs or dairy that do not align with the detergent used. This is another instance where it is important to know which detergent is best for your machine and water supply.

CONCLUSION

Because warewashing is such an integral part of any foodservice operation, it is essential to do your homework and be prepared and informed before installing a system. Remember to create an integrated system that conforms to the size, scope and infrastructure of your operation and to all health and sanitation rules.

Proper warewashing requires adhering to one of the golden rules of doing business: You get what you pay for. A cheap program with cheap equipment will result in poor results, unhappy employees and even unhappier guests. Do it right and you have a cost-effective program that produces spotlessly clean dishware that reflects pride in your business.

Work with experts to help you get the right system installed in the right way. Use major

service providers who guarantee their products and provide a solid service agreement.

Study and view different types of machines. Test them out when possible.

Know your facility’s utilities regarding water supply and water type, electrical and

plumbing specifications and capacity.

Use an environmentally safe system to eliminate contamination and pollution.

Ideally, foodservice operators should look to a warewashing company for chemicals, service, expertiseand maintenance programs. You want a provider who can take the program and own it for you in your restaurant so you can concentrate on guest relations and food quality. Let the experts manage the program for you and your entire business will benefit.



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About Us

Much more than Group Purchasing

Axis Purchasing offers you multi-billion dollar group buying power for food, beverages and supplies without the restrictions of other organizations or the requirement to change distribution partners.

Our programs include manufacturing incentives, low contract pricing and a deep analysis of your purchases so you get more product options. You maintain complete control; keep your current distributor with no out of pocket expense. Best of all we provide a complete satisfaction guarantee.

Our happy customers appreciate our true value, not just low prices. That is why we have quicklygrown to thousands of foodservice locations across North America.

Give us a call 703-310-7607 or drop us a line at [email protected] today.


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Axis Purchasing – Inventory Control – Basics for Foodservice · PDF fileWarewashing – An In-Depth Analysis ... impact your bottom line and many other parts of your business