ifma facility fusion 2011 everything you wanted to know about foodservice ice final

Everything You Wanted to Know About (Foodservice) Ice But Were

Afraid to Ask Michael Rice

Senior Product Marketing Manager Follett Corporation

Meet Our Presenter:MICHAEL RICE

• Senior Product Marketing Manager – Follett Corporation• Responsible for icemakers & ice & water dispensers• R & D, strategic planning, business development, and marketing• Adjunct faculty at DeSales University – “Ethical Issues in the Workplace”

FOLLETT CORPORATION

Easton, PA based manufacturer providing innovative ice related equipment and high performance refrigeration products that promote health, safety, and well-being in foodservice, healthcare, and office environments for over 60 years

What is Ice?

What is Ice?

ICE IS FROZEN WATER

What is Ice?

ICE IS FOOD!

Agenda• Ice types

• Ice machines

• Ice storage and transport

• Ice for office break areas

ICE TYPES

Three most important for food service

• Cube

• Extruded (also known as nugget)

• Flake

Basic Ice Types

Cube Ice

• Virtually clear, hard ice

• Various shapes & sizes depending on specific machine

• Historically, most popular ice type

• Typical capacities – 100 to 2000 lbs/day

• Used for beverages and general cooling

Cube Ice• Water is pumped over a cold

evaporator plate

• Water freezes into depressions in the evaporator

• Unfrozen water collects in sump and recycles over evaporator

• Defrost cycle adds heat to loosen the ice from the evaporator plate

• Ice falls from plate and collects in storage bin or dispenser

• Sump water discharged every few cycles

Extruded Ice

• Softer, chewable ice

• Defined as compressed flaked ice and commonly referred to as nugget ice

• Various shapes, sizes and hardness depending on machine

• Typical capacities up to 1500 pounds per day

• Nugget ice can be used just about anywhere cube ice is used

• Potentially better for smoothies

Extruded Ice

• Water freezes on the inside wall of a cylindrical evaporator

• Slowly rotating auger harvests ice as flakes from the evaporator wall

• Ice is extruded through a nozzle into small shapes

Extruded Ice

CUSTOMER-PREFERRED 2:1 OVER CUBES

soft, chewable texture

half the population likes to chew ice

PAGE ONE

Chew This Over: Ice Sells Like Hot Cakes

Fans Buy It by the Cup At Fast-Food Restaurants; Nugget Machine Was KeyBy ILAN BRATJanuary 30, 2008

Flake Ice

• Soft, snow-like texture, easily molded to shape

• Flakes continuously harvested from cylindrical evaporator wall but no compression

• Used for produce and seafood displays, salad bars

Icemaker Considerations

• Production Capacity

• Types of Condensing

• Efficiency

• Sanitation

• Space Utilization

• Controls

• Sizing Guidelines

Production Capacities• Commercial icemakers used in food service have wide

range of production capacities – from 50 to over 2000 lbs per day.

• Actual production is affected by ambient air and water temperatures.

PRODUCTION CAPACITIES

FOR 1000 LB ICEMAKER

Type of Condensing

AIR COOLED

Air cooled condensing uses a fan to draw air over condensing coils full of hot refrigerant to remove the heat that is extracted from the water in the process of making ice –

• Comprise 85% to 90% of the market (due partly to ease of installation)

• Operate best in cooler air temperatures with good ventilation

- high ambient temperatures reduce capacity

- poor ventilation can overwork icemaker and reduce compressor life

Type of Condensing

WATER COOLED

Water cooled condensers use water (or sometimes glycol) in the condensing coils to remove the heat extracted in ice making

• Good choice when ambient air temperature is high, proper ventilation is difficult to attain, or heat should be kept out of the area

• However, requires 100-150 gallons of water per 100 pounds of ice

• Wasteful unless used with a closed loop recirculation system that uses a heat exchange device to remove heat

• More efficient systems re-circulate water through a heat exchange device and reuse

Self-contained• Icemaker evaporator,

compressor, and condenser are all within the unit

- Smaller icemakers (500 pounds per day of capacity or less) are almost exclusively self-contained

- Lower cost, easier installation

Type of Air-Cooled Condensing

Remote condensing• Evaporator, and usually

compressor, are in a main icemaking unit

• Condenser (and sometimes compressor) located remotely, usually up on a roof

• Removes heat from the facility but is more expensive

• Common with capacities over 1000 pounds per day

Type of Air-Cooled Condensing

Trend to placing both compressor and condenser in a remote location

• Option available that puts both the compressor and condenser (sometimes referred to as the “high side” of the system) in a remote location

• Removes all heat and noise from dispenser area

Type of Air-Cooled Condensing

Icemakers by Condensing Type

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

<500 500-1500 >1500

Capacity, #/day

Water cooled Air-cooled Remote condenser Air-cooled Self contained

Follett estimate

Type of Condensing

Ice Machine Efficiency

Energy

Water use

Heat rejection

Ice Machine Efficiency

Energy

• About 250 billion pounds of ice is used in foodservice yearly

• Industry-wide, icemakers consume over 1500MW per year – could power Las Vegas

• Replacing inefficient icemakers is always a good choice

• Considering more utility efficient technology also offers a creative approach to enhance sustainability

EnergyEnergy Consumption,

kwh/100# ice 1

Average savings with extruded

icemakers

Capacity

Icemaker TypeAverage

cube-type icemaker

Average extruded icemaker

%$ per year

2

400# per day

Air-cooled self contained 7.3 5.9 19% $130

1000# per day

Air-cooled self contained 5.7 4.7 18% $220

Air-cooled remote condensing

5.5 5.0 10% $130

1400# per day

Air-cooled self contained 5.2 4.1 21% $360

Air-cooled remote condensing

4.9 4.1 16% $290

1 at 90°F air and 70°F water 2 at national average of $0.10/kwh and 75% utilization• Energy costs can be reduced 15-20% and natural

resources can be preserved with extruded ice

Water

Water availability is becoming more of an issue nationwide• Icemakers consume over 50 billion gallons of water per year

• Over 20 billion of that is wasted – enough to serve Tampa

• Increase interest in extruded ice due to very low water usage

WaterWater Consumption, gallons/100# ice 1

Average savings with extruded

icemakers

Capacity

Icemaker TypeAverage

cube-type icemaker

Average extruded icemaker

%$ per year

2

400# per day

Air-cooled self contained 22 12 45% $55

1000# per day

Air-cooled self contained 22 12 45% $110

Air-cooled remote condensing

21 12 43% $105

1400# per day

Air-cooled self contained 21 12 43% $135

Air-cooled remote condensing

21 12 43% $135

1 at 90°F air and 70°F water 2 at national average of $5/1000 gallons and 75% utilization• Water use can be reduced 10,000 - 25,000 gallons

per year with extruded ice

Heat Rejection

• Extruded icemakers can reduce peak AC design requirements by almost 1/2 ton

Ice Machine Heat Rejection, Btu/hr

400#/day 1000#/day 1400#/day

Typical cube-type machine

7,500 16,000 21,000

Typical extruded ice machine

5,000 11,500 16,000

Reduction with extruded ice machine

33% 28% 24%

Why are Extruded Ice Machines More Efficient?

• Extruded icemakers are continuous operating machines instead of batch-type machines

o No cyclic defrost

• There is no re-circulating sump water that is regularly dumped down the drain – almost all the water is used for ice

SanitationDirty ice can make you sick

BIG NAMES MISHANDLE ICE IN

CHICAGOThe Chicago Sun Times recently tested

ice at 49 Chicago restaurants – from fast

food to casual dining.

 The newspaper found that 42% of the

samples were contaminated with fecal

bacteria which mean employees aren't

properly washing their hands after going

to the bathroom.

Are food-handlers taking the same precautions with ice?

The forgotten foodIce one of the staples of summer – it’s in our drinks, in our coolers, at our parties. And chances are, you don't think twice about how

safe it is. But one boy got a virus from ice that later caused his death. Victoria Corderi has a

Dateline Hidden Camera Investigation.

Dateline NBC

13 Investigates

Hold the Ice

Updated: Feb 5, 2008 04:53 PM

EST

Bob Segall/13 Investigates

Scientists say improper hand

washing, food handling and

equipment maintenance are to

blame for high bacteria levels

found in local restaurant ice.

SanitationDirty ice can make you sick

Sanitation

• Improved ice machine design and operation

• Using antimicrobial materials of construction

• Making icemakers easier to clean, e.g. automatic cleaning systems

• Improving ice maker flushing systems

• Automatic filling of dispensers vs manual filling

May be necessary in certain settings

• Concentrated times of peak usage

• Only one icemaker for multiple dispense/use locations

Potential safety hazard• Loading takes place over 6’

above floor• Requires multiple trips with

heavy bucket• Spilled ice on floor – slip and

fall

Potential sanitation concerns• Opportunities for

contamination

Manual Fill

• Minimizes ice sanitation issues

• Works well in self-serve applications

• Potential issues- Difficult to clean and sanitize bin- Combined height of may not fit under ceilings or soffits.

- Compromises aesthetics

Top-Mount Automatic Fill

New ice making developments provide improved access to dispensers for cleaning

Shallower machines with remote refrigeration allow more access to dispenser ice storage area

Top-Mount Automatic Fill

Satellite-FillTM

• Icemakers can be located up to 75 ft away and still automatically fill a dispenser

• Removes heat/noise

• Improve aesthetics

Satellite-FillTM

• Icemakers can be located up to 75 ft away and still automatically fill a dispenser

• Removes heat/noise

• Improve aesthetics

• Allows full access to dispensers for better cleaning and sanitation

• Satellite-fill allows user to maximize bin storage capacity per square foot of floor space

Space Utilization

Space Utilization

Fill two dispensers with one ice machine

• Save space and equipment costs

• Higher efficiency operating one larger icemaker

• Higher hourly capacity to dedicate to critical dispense area

Smart Machines

Intelligence to understand operating conditions and adjust machine operation accordingly

• Different water conditions

• Time of day

• Ice levels in bins or dispensers

Remote monitoring

• Allows central control and dispatch for service

• Find problems before operators lose ice

• Choosing the right icemaker involves understanding

Number of people served

Ice machine capacity

Dispenser or bin ice storage capacity

Cup size

Beverage cooling approach

• All ice machine companies have sizing guidelines available to help

General Ice Sizing Guidelines

CAFETERIAS• Plan for peak daily customer total • Base requirement of .75 lbs per

person served – plan for peak day customer total

• Double base amount (1.5 lbs per person total) if cold plate used to cool drinks

• Double again if free refills offered (1.5-3.0 lbs per person total depending on cold plate use)

• Self-serve generally requires more ice

• Salad bars - Add 35 pounds per day per sq. ft.

General Ice Sizing Guidelines

Dispenser size, rated # of storage

Ice Machine Capacity (70/50)

Beverage cooling Yes No Yes No Yes No Yes No Yes No

Max drinks/day that can be served with auto-fill without running out of iceAvg cup size

16 675 1525 750 1700 800 1800 850 1900 950 2125

22 500 1100 550 1225 575 1300 625 1375 700 1550

32 325 750 375 850 400 900 425 950 475 1050

44 250 550 275 600 275 650 300 675 350 775

Assumes 40% of ice consumed between 11 a.m. and 2 p.m., cups half full of ice. Other conditions can be modeled

400150 200 250 300

1000 1000 1000 1000 1000

General Ice Sizing GuidelinesIce machine / dispenser trade offs

Two major choice drivers:(1) Cost

Size bin for peak day needs

Size ice machine for average daily needs(2) Footprint

Smaller bin requires significant increase in icemaking production

Ice production costs 2 to 3 times more than ice storage

1650 pound ice storage bin

1250 pound icemaker

Representative list price $17.5K

Representative list price $14K

825 pound icemaker

825 pound icemaker

Example 1

Example 2

General Sizing GuidelinesIce machine / storage trade-off

• Issues– Safety– Sanitation– Labor Efficiency

• Options– Slope front bins– Upright bins– Gravity feed bins– Ice Transport - Carts and totes

Ice Storage and Transport

Safety

•Large potential for back injuries from hauling and dumping heavy buckets

• Potential for employee and customer falls as a result of ice spillage from scooping and dumping ice into dispensers

• Of foodservice premises liability verdicts:†41% were between $10,000 - $99,999 USD47% were between $100,000 and $5 million USD

Safe and Sanitary Ice

† (Personal Injury in the Hospitality Industry, JVR 2000)

Sanitation

– Hand scooping and carrying ice can create a breeding ground for bacteria

– Care must be taken even dedicated containers to make sure they are sanitized and not used for other purposes!

† (Personal Injury in the Hospitality Industry, JVR 2000)

Safe and Sanitary Ice

Slope Front Bins

• Named for the angled or sloped front

• Access door at top of bin – last ice in is first ice out

• Width: from 22” to 52”

• Plastic or stainless steel exterior

• Stainless steel or polyethylene liner

CHARACTERISTICS

APPLICATIONSStorage capacity from 200 to 1000 lb

Can accommodate all ice types

Slope Front Bins

Safety• Large potential for back

injuries

• Lots of spillage

Labor• Slow ice removal

Slope Front Bins

Sanitation and ice

quality• Last ice in is first ice out

• Old ice in bottom of bin

• Stale off-taste and smell

• Breeding ground for

bacteria

• Potential for contamination

when scooping LIFO

Upright Bins

• Access door at the bottom of bin – first ice in is first ice out

• Width: from 30” to 96”• Aluminum or stainless steel exterior • Stainless steel or polyethylene liner

CHARACTERISTICS

APPLICATIONS• Storage capacity from 500 to 5000

lb

• Can accommodate all ice types

Upright Bins

Labor• Easier removal with scoop or shovel than slope front bins

• Shovel ice removal is twice as fast as scoop

Safety• Easier access to ice• Safer when breaking ice bridges• Fewer motions• Less ice on floor – reduced slips and falls

Sanitation• FIFO – first ice in is first ice out• Constant ice turn-over

Gravity Feed Binsand Carts

•Front chute deposits ice by gravity into transport cart or tote•Width: from 30” to 90”•Stainless steel exterior •Stainless steel or polyethylene liner•Transport 75-240 lb of ice at a time

CHARACTERISTICS

APPLICATIONS• Storage capacity from 500 to 4500

lb• Not for use with flake ice• Easy movement of ice throughout

facility

Gravity Feed Binsand Carts

CHARACTERISTICS• Bottom chute deposits ice by gravity into transport cart

• Storage capacity: from 500 lbs to 4000 lbs

• Width: from 30” to 90”• Stainless steel exterior • Stainless steel or polyethylene liner• Transport 150-240 lb of ice at a time

• Storage capacity from 500 to 4000 lb• Can accommodate all ice types

APPLICATIONS

Gravity Feed Binsand Carts

Labor• Five times faster than

shoveling/scooping• $1500 annual labor savings when moving

1000 lb of ice/day• Conducive to employee retention

Safety• Safest transport of high quantities of ice• Totes limit weight lifted to 25 lb• Less ice on floor - reduced slips and falls

Sanitation• Highest degree of sanitation • Reduced handling• Dedicated ice-only cart and Totes

Design Considerations

Corrosion• Stainless steel interiors can corrode as it reacts with chlorine above the ice line. The following measures can impact corrosion

• Filtering water reducing chlorine

• Polyethylene liners will resist corrosion as compared to stainless steel liners

• ABS bin tops have superior corrosion resistance to stainless steel tops

• Exposed stiffeners on the tops that are difficult to clean around promoting corrosion

Design Considerations

Installation

• Satellite-fill icemakers can increase ice storage capacity in low ceiling heights

• To avoid damage to the drains during handling, look for a bin that doesn’t have a drain that protrudes from the bottom of the bin

Design Considerations

Floor drains• Care must be taken to place floor grates in front of bin legs

• Floor should slope toward grates and drains

• Floor drains for gravity feed bins may not need to run the length of the front of the bin like standard slope front and upright bins

• For wheeled carts, narrow grate drains are recommended, such as the ADA grate by Sani-floor

Design Considerations

Door• Doors that require a catch to stay open are harder to use than those whose hinges will keep it open once lifted up

Door gasket• Molded-in-place gasket doesn’t need to be removed for cleaning and won’t be lost or require replacement

Labor• Slow, difficult to transport• Small amount carried at one time• Multiple trips

Safety• Large potential for back injuries, spillage and slippage

Sanitation and ice quality• Higher risk of ice contamination• Difficult to store; buckets often nested/stacked on floor

• Possibility that buckets might be used for other jobs

Ice TransportPickle Buckets

Labor• Slow, difficult to transport• Small amount carried at one time• Multiple trips

Safety• Handle grip at bottom allows for easier tipping• Potential for back injuries, spillage and slippage

Sanitation and ice quality• Non-nesting with hook to hang upside down for drainage

• Marked for ice usage only

Ice TransportDedicated ice buckets

CHARACTERISTICS• Ice Totes allow quick dispense of ice

into salad bars and dispensers.

• Insulated carts are particularly suited for catering operations. Insulation maintains ice with minimal meltage and staff can work directly from the cart.

• Insulated carts for moving large amounts of ice. Low height allows easy access for shoveling into displays.

Ice TransportTotes and Carts

Labor• Four times faster ice transport

Safety• Less potential for back injuries and slippage

• Safe transport of 75-240 lbs of ice• Limits lifted weight to 25 pounds

Sanitation• Dedicated ice-only cart and Totes• Non-nesting Tote design• Cart cover for sanitary transport

Ice TransportTotes and Carts

Ice in Offices

• Outside of the kitchen, ice can probably be found in about ½ the offices

• Ice is a valuable amenity that employeesappreciate– Encourages hydration– Keeps drinks colder longer– Supports a variety of beverage offerings

to help keep employees “in the office”

• Plan for about 0.25 to 0.50 pounds (0.1 to 0.2 kg) of storage and a minimum production of 1-2 pounds (0.5 to 0.9 kg) per person per day

Ice in Offices

• Popular equipment to provide office ice includes – Refrigerator-freezer icemakers– Undercounter icemakers– Icemakers on bins– Ice and water dispensers

• Sanitation is again the key– Focus on equipment that minimizes cross-

contamination

Ice in Offices

• High quality commercial grade appliances– Capacities to serve up to 350

people

• Filtration for high quality water– Good economical and sustainable

solution to bottled water

Ice and Water Dispensers

• Sanitary, hands-free dispensing– Lever, button, touch-less

infrared

• Highly efficient– Low electricity and

water use

Ice and Water Dispensers

• Use icemakers that will automatically fill hands-free dispensers wherever possible

• Clean the icemaker in accordance with the manufacturer’s recommendations

• Have employees wash their hands before handling ice

• Use ice storage and transport equipment that minimizes the chances of contamination

In Summary – Take Care of Your Ice!

• Clean the inside of the ice storage equipment frequently

• Wash scoops and shovels frequently and hang them away from contaminating surfaces

• Use only ice-dedicated buckets to transport ice and wash frequently

• Never nest ice transport buckets inside each other

• Prohibit staff from storing food or beverages in any ice storage bin

In Summary – Take Care of Your Ice!

For attending this educational offering at IFMA’s Facility Fusion.

Thank You!