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