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Section Title

Introduction ........................................................................................................................................................ Page 4 Work Space Dimensions ............................................................................................................................. Page 5 Kitchen Flow Chart ........................................................................................................................................ Page 6 Kitchen Equipment requiring Grease Management Systems ................................................ Page 7

1 Spatial Planning 1.1 Spatial requirements ...................................................................................................................................... Page 8 1.2 Work Flow ........................................................................................................................................................... Page 8 1.3 Provisions for adequate space ................................................................................................................. Page 9

2 Food Safety 2.1 Temperature Measuring Devices ........................................................................................................... Page 10 2.2 Food handling ..................................................................................................................................................... Page 10

3 Water Supply and Drainage 3.1 Water supply ...................................................................................................................................................... Page 11 3.2 Drainage ................................................................................................................................................................ Page 11 - 21

4 Fixtures, Fittings and Equipment 4.1 General requirements ................................................................................................................................... Page 22 4.2 Installation ............................................................................................................................................................ Page 22 4.3 Specificrequirements.................................................................................................................................... Page 23 4.4 Materials ................................................................................................................................................................ Page 23 4.5 Cleaning sanitizing and maintenance ................................................................................................... Page 23 - 25

5 Waste 5.1 Disposal systems .............................................................................................................................................. Page 26 - 27 5.2 Storage ................................................................................................................................................................... Page 27 - 28 5.3 Location ................................................................................................................................................................. Page 28 5.4 Flooring .................................................................................................................................................................. Page 28 5.5 Cleaning ................................................................................................................................................................. Page 28

6 Flooring 6.1 Floorfinishesandserviceability.............................................................................................................. Page 29 6.2 Floor drainage .................................................................................................................................................... Page 29 9.3 Floor and wall intersections ...................................................................................................................... Page 29 7 Walls and Ceilings 7.1 Ceilings ................................................................................................................................................................... Page 30 7.2 Walls ........................................................................................................................................................................ Page 30

8 Ventilation 8.1 Natural ventilation .......................................................................................................................................... Page 31 8.2 Exhaust systems ................................................................................................................................................ Page 31 8.3 Airflowplananddesign................................................................................................................................ Page 32 8.5 Environmental considerations .................................................................................................................. Page 32

Index

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Section Title

9 Lighting 9.1 General Requirements .................................................................................................................................... Page 33 9.2 Natural&ArtificialLighting........................................................................................................................ Page 33 9.3 Reflectance............................................................................................................................................................ Page 33 9.4 Light Fitting Considerations ....................................................................................................................... Page 34 9.5 Emergency Lighting .......................................................................................................................................... Page 34 9.6 Environmental Considerations ................................................................................................................. Page 34

10 Storage 10.1 Storage Requirements .................................................................................................................................... Page 35 10.2 HazardousSubstances.................................................................................................................................... Page 35

11 Pest Control 11.1 Prevention ............................................................................................................................................................. Page 36 11.2 Insect Control ..................................................................................................................................................... Page 37 11.3 Monitoring ............................................................................................................................................................. Page 37

12 Signage 12.1 Emergency Signage ........................................................................................................................................... Page 38 12.2 Hygiene Signage ................................................................................................................................................. Page 38 12.3 Equipment Signage ............................................................................................................................................ Page 38 13 Staff Amenities 13.1 Storage of Personal Items ............................................................................................................................ Page 39 13.2 Changing Rooms ............................................................................................................................................... Page 39 13.3 Toilets ....................................................................................................................................................................... Page 39 13.4 StorageofOfficeMaterials .......................................................................................................................... Page 39 13.5 Hand Wash Basins ............................................................................................................................................. Page 39

14 Fire Safety 14.1 Emergency Procedures .................................................................................................................................. Page 40 14.2 Emergency Devices .......................................................................................................................................... Page 40 - 44 14.3 Fire Extinguishers ............................................................................................................................................ Page 41 14.4 Staff Training for Emergencies .................................................................................................................... Page 44 15 Access & Agress 15.1 Provision for Egress ......................................................................................................................................... Page 45 15.2 ProcessforPeoplewithDisabilities...................................................................................................... Page 45

16 First Aid 16.1 First Aid Kits ......................................................................................................................................................... Page 46 16.2 First Aid Personnel Required ...................................................................................................................... Page 46

Index

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Design points for Commercial Kitchens developed from our experience in kitchen design commercial drainage solutions with over 60 years experience. The aim of this guide is to provide the hospitality (including managers, proprietors, designers and commercial kitchen users) with recommendations for implementing efficient, safe and best practice for the hospitality industry. Within each section are precautions, processes and recommendations that contribute to the efficient running of a commercial kitchen, whether it is for small, medium or large premises.

Theseguidelinescanbeusedwhendesigningnewkitchensorrenovatingexistingcommercialpremises.

Theypresentthehospitalityindustrywithrecommendationsthatwillcontributetosafeandefficientproductionofuncontaminated food.

They are guidelines only.

The Law in your Kitchen

Therewasatimewhenallchefshadtoworryaboutwascookinggoodfoodandmeetingthegrossprofittargetontopofkitchencosts.Chefsmustalsobeawareofthecurrentlegislationconcerningwastemanagementinhiskitchen.IntheUK,themostimportantfoodhygieneregulationsforyourbusinessare:

•Regulation(EC)No.852/2004onthehygieneoffoodstuffs.•TheFoodHygiene(England)Regulations2006(asamended)(andequivalentregulationsinScotland,Wales&NorthernIreland).•TheBuildingAct1984.•FoodSafetyAct2006.•EnvironmentalProtectionAct1990.•WaterIndustryAct1999.

Notonlymustthechefbeawareoftheseregulations,theymustmakesuretheirpremisesandstaffcomplieswiththese regulations.

CE Marking

Thisisthesmall“CE”badgethatallpoweredcateringequipmentsoldintheUKandEuropemustcarry.ItmeansthatthemanufacturerhascertifiedthatitmeetsEuropeanUnionsafetyand,insomecases,performancestandards.The EU standards are among the strictest in the world and are drawn up to ensure that kitchen staff have the least possibleriskofinjury.

ReputablebrandsofcateringequipmentboughtfromreputabledealersshouldalwayshavetheCEmark,butoccasionallythereisequipmentofferedforsalewhichlooksthepartbutlacksthatall-importantCEbadge.Theregulationrecognizesthat many kitchens have well-maintained old equipment that predates the introduction of CE marking. That is why the legalrequirementforkitchenequipmenttobeCEmarkedappliesonlytoequipmentmanufacturedafter1995.

Introduction

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ColdStores

Service CounterJanitorial

Stores

StorageArea

ServiceDoor

Wash Area

UndercounterRefrigeration

Vegetables

Quadwash

Beverage

Grease Trap

Prep Area

Quadwash

Quadwash

Combi Oven

Waiter Traffic

Potato Peeler Laundry Room Outside Yard

Grease Management Systemrequired if the area is used to

wash down equipment

Starch Separator

WashingMachines

PotatoPeeler

Ironing

Dryer

Gully

Bunding

BinsBinsLint Separator

Steam OvenGrease Trap

Meat Poultry FishWaste PipeGrease Trap

Cooking Equipment

Cooking Area

Pot Wash

CrockeryStores

DryStoresDish

Washing

Dish Washer

Introduction Work Space Dimensions

Itisrecommendedthatprovisionbemadeforthefollowing:

Clearances

•Upto1200mmclearanceinfrontofstorageareaswithaslidingdoor.•1200mmx1200mmclearanceinfrontofotherroomswithswingingorfoldingdoors(i.ediningroom/servicedoors).•Betweenworksurfaces900mm.

Suggested Layout

Thisisasuggestedlayoutforalargekitchenservicingarestaurant.Thelayoutcanbemodifiedtosuitsmallkitchens,pubsandclubsor expanded to suit larger commercial kitchens.

AllequipmentconnectedtowasteshouldbetrappedandranthroughaGrease Management System.

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Note:Thearea3,5&7shouldbeseparateandnotcrossoverintheflowdesignofakitchen.

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Macerators should not discharge into the drainage system. A separate collection tank for this waste is required. Adrainfromthistankisadvisable.Pleaserefertopage12(designconsiderations)forfurtherinformation.

Note:Thearea3,5&7shouldbeseparateandnotcrossoverintheflowdesignofakitchen.

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This section sets out criteria for the spatial planning of commercial kitchens. A well-planned kitchen will save time and effort in food preparation and reducing cross contamination while create a safe work environment.

1.1 Spatial Requirements

Awellplannedkitchenshould:

•Provideadequatestorageforrawmaterials.•Provideadequatespaceforfoodbeingprepared.•Provideadequatespacefoodawaitingservice.•Provideadequatestorageforequipment,utensils,crockeryandcutlery.•Beefficientandeffectiveintermsofmovementofstaff,equipment,materialsandwastemanagementsysteminplaceFood,Oil&Grease(F.O.G)•Provideanareaforcheckinginstock.•Janitorialstoreforkitchen,withjanitorialsinkinplaceandchemicalstore.

Tomaintaineffectivemovementthroughspaces,theareaperpersonaccordingtouseoftheequipmenthasbeenestablishedbytheBuildingAct1984/Workplace(Health,SafetyandWelfare)Regulations1992.Itisrecommendedthatinakitcheneachperson needs 10m2.

1.2 Work Flow

Thepremisesshallbedesignedsothatthereisacontinuousprogressionoffoodfromdeliverytostorage,throughtopreparationandthefinishedproduct,withnocrossovertoavoidcrosscontamination.

1.2.1 Food Delivery or Receiving

Thisincludesthereceivingofpurchasedgoods,whichinvolves:handling,checking,recordingorstorage.Someofthesefunctionsmaybecombinedornotneededdependingonthesizeofthekitchen.

1.2.2 Storage

Theamountofstoragespaceandthetypeofstoragewilldependon:•Thesizeofthekitchen.•Menu.•Thevolumeofbusiness.•Deliveryfrequency.•Thelengthofstorage.•Thetypeofstorage(frozen,refrigeratedordry).Storageofmeats,poultryandfishshouldbetakenintoconsiderationwhendesigningthekitchenandkeptseparatefromdryfoods,vegetables,fruitandpastry.

1.2.3 Preparation and Cooking

Themainpreparationareasinfoodpremisesarefor:•Meatpreparation.•Poultrypreparation.•Fishpreparation.•Vegetablepreparation.•Pastry/dessertpreparation.

Allfoodpreparationareasshouldbeseparatefromthecookingarea.Eachpreparationareashouldhaveonesinglesinkperstationseparatedbyaphysicalorairgaptoreducecrosscontamination.Handbasinsshouldbeintheseareas.(SeePage5)

Section 1 Spatial Planning

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1.2.4 Clean Crockery

Storageforcleancrockeryshouldbeclosetothewashingupfacilitytominimizeexcessmovementaroundthekitchenand ideally in a separate room due to the air pollution in a kitchen.

1.2.5 Food Service

Thetypeofservice(alacarte,fastfood,caféorbanquet)willdirecthowtheservingfunctionisperformed.Themostcommon service is plate service, which requires pick-up points next to the cooking area. The pick-up point arrange-mentshouldhaveamethodtokeepthedisheswarm/cold.Thereshouldbeaseparatepick-uppointforchilledfoodsuchasdessertstobeheldinarefrigeratedcabinet.Thepick-uppointarrangementiscriticalforanefficientinandoutflowofwaitertraffic.Itisessentialtodesignkitchenflowofservice/waiterstrafficinthekitchenlayout.Waitingstaffshouldnothaveeasyaccesstothecookingareaorpreparation area.

1.2.6 Waste Food and Dirty Crockery

The dish washing area positioning is vital to the successful operation of any kitchen. The design of the dish washing area should have a large drop off area. This area should have the facility to cope with the waste from plates. This will dependonthenumberofcoversandmenu.

Thefollowingisasuggestedlistofpossiblecleaning/storingmethodsandequipment:

•Stainlesssteelrackingforpotsandpans.Openforeaseofcleaning.•Stainlesssteelrackingforplatesinseparateenclosedarea.•Cutlerystorage.•Storageformopsandchemicalsandajanitorialsink.•Adequatesinks.Whenpositioningsinks,drainageshouldbeaddressede.g.Sinksshouldbeinline,inordertoreducethenumberofGreaseTrapsrequired.•Pre-washhose.•Extractionsystem.•Wastedisposalbin(differingbinsforrecyclables).•WasteManagementSystem.•HACCP-Regulation(EC)No.852/2004onthehygieneoffoodstuffs.

Food,Oil&Greasearebyproductsofthekitchenandcreatedrainageproblemsinkitchens.Thesesubstancescreatemajorproblemsfortreatmentplants.Thebestmethodofcontrollingthisisatsource.Thisshouldbeaddressedatplanningstagetopreventproblemsfromwatercompanies,environmentalagenciesandpublichealthinspectors.

1.3 Provisions for Adequate Space

Spaceshallbeprovidedonthepremisesforstafftohandlefoodandperformotheractivitiesthatarepartofthefoodbusiness.

Spaceshouldbeprovidedfor:

•Foodpreparationandservice.•Separationofrawfoodpreparationfromcookedfoodpreparationandotherready-to-eatfoodpreparationareas.•Washingandsanitizingoperationsforutensilsandequipment.•Separationoffoodstorageandhandlingareasfromareasforchemicalstorage,toilets,wastestorage,officeareas and other areas used for activities that could contaminate food or food preparation areas.•F.O.Gmanagementsystems.

Itisrecommendedthatwashhandbasinsshouldbelocatedinthedifferentareaswherefoodishandlede.g.betweenprepareaandcookingarea.Washhandbasinsshouldnotbeincludedinworktops.Theyshouldbeseparatedwithaphysicalorairgapinbetweentominimizecrosscontamination.

Section 1 Spatial Planning

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This section covers the food safety program, food handling controls such as food processing, food display, food packaging and transportation of food, as well as food handling.

Glossary

Food-borne disease: Adiseasethatislikelytobetransmittedthroughconsumptionof contaminated food.Food safety program: A program that is set out in a written document, and kept at the food premises, which includes records of compliance and other related actions.Potentially hazardous Food: thathastobekeptatcertaintemperaturestominimizethegrowthof anypathogenicFood:micro-organismsthatmaybepresentinthefood or to prevent the formation of toxins in the food.Process: The activity of preparing food for sale including chopping, cooking, drying, fermenting, heating, pasteurizing, thawing and washing, or a combinationoftheseactivities.Ready-to-eat food: Food that is consumed in the same state as that in which it is sold and does notincludenutsintheshellandwhole,rawfruitsandvegetablesthatare intendedforhulling,peelingorwashingbytheconsumer.Temperature control: Maintaining food at required temperatures.

2.1 Temperature Measuring Devices

Atemperaturemeasuringdeviceneedstobereadilyaccessibleandmustaccuratelymeasurethetemperatureoffoodto+/-1°C.

Thetemperatureoffoodshouldbemaintainedat:

•8°Celsius,orbelow.Thisistominimizethegrowthofinfectiousortoxigenicmicro-organismsinthefoodsothatthesafetyofthefoodwillnotbeadverselyaffectedforthetimethefoodisatthattemperature;or•63°Celsius,orabove;oranothertemperature,onlyifthefoodbusinesscandemonstratethatthemaintenanceofthefoodatthattemperaturefortheperiodoftimeforwhichitwillbesomaintained,willnotinanywayaffectthemicrobiologicalsafetyofthefood.

2.2 Food Handling

Staff must wash hands as they move from different area’s in the kitchen e.g. preparation to cooking. This will help reducecrosscontamination.Preparedmeats,poultry,fishandvegetablesmustberefrigerateduntilneededandheldinarefrigeratedundercounterunitinthecooking/preparea.

Ideally

•Usecolourcodedchoppingboardsandknivesforrawandready-to-eatfood.•Washyourhandsbeforepreparingfoodandafter.•Keeprawandready-to-eatfoodapartatalltimes.

Anystaffsufferingfromdiarrhea/vomitingwithinhoursmustnotbeallowedintothekitchenareaunderanycircumstance. Itmustbeassuredthatanystaffmemberignoringthissafetyrequirementcanbesubjecttoinstantdismissalalongwith their manager for condoning this. Staff can only return to work two days after the symptoms have passed.

Section 2 Food Safety

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This section refers to water supply and drainage in a commercial kitchen.The design and installation of water supply and drainage systems must comply with statutory requirements. Itisrecommendedthatqualifiedhydraulicengineersand/ortradespersonsareengagedtoensurecompliance.

GlossaryNon-potable water: Waterthatisnotsuitableforhumanconsumption(greywater).Bio-film: Itisthecoatingfoundinsidethewastepipeswherethebacteriathrive.

3.1 Water supply

Watersupplyisrequiredforthefollowing:

•Drinking.•Cooking..•Icemaking.•Cleaning.•Sanitizing.•Personalhygiene.•Firesuppressionsystems(firehydrants,hosereelsandsprinklersystems).

Separatenon-potablewatersuppliesareoftenusedforfiresuppressionsystemse.g.recycledrainwater.Hotwatermustbestoredataminimumof60ºCtopreventgrowthofbacteriasuchasLegionella.(Seepage24).Waterpressuremustbeadequatetomeetallthedemandsofthecommercialkitchen.

3.2 Drainage

Waste removal at source is a simple concept in a highly complex world

Ifwastewhichcanbedealtwiththroughcompostingorlandfillisnotdumpedintooursewagesystemstheloadingon the system is reduced.Itshouldalsobeconsideredthatbysavingwatere.g.greywaterforirrigation,etcandthenaturalreductionsduetocostsavingactivitieslesswaterwillflowthroughpipesystemstowashdownsolidsandtodilutechemicalsweallowinto pipes.Bacteriaarethekeytoaproperfunctioningdrainagesystem.Bio-filmonthepipesassiststhepassageofflowingsolidsandreduceschancesofblockagescausedbyorganicmaterials.Wearenotreferringto“commercialbacteria”dosedtoenhancedrainagesystemsbutthenaturalbacteriacontainedinalllivingorganisms.

Theaerobicbacteriainpipesandtanksrequireoxygentocarryoutitsfunctionofdigestingorganicmaterialsflowingthrough pipe lines

•Theoxygensupplycanbedamagedbyexcessiveuseofchemicalsoroil(whichcontainsnooxygen)thiscanremovetheoxygensupplycoatingpipesandorganicseffectivelykillingbacteriabyoxygenstarvation.•Thiscanbebestobservedinpumpingchamberswheresolidbuildupsformfloatingraftsordebriswhichwillnotsinkasoileffectivelywaterproofsfloatingsolidsandbacterialactionisdramaticallyreduced.•Wastedisposalofsolidandliquidformshavebecomeamajorprobleminmanycities.Thecostofsupplying services to this area of our life style is spiraling. Commercial kitchen management is well advised to ensure that the staff are aware of the need to reduce waste and how to dispose of it in a regulated manner.•CommercialkitchendesignersandarchitectshaveadutyofcaretotheirclientsandshouldincludeFood,Oil&Grease(F.O.G)managementintheirdesigns.

Authoritiesandmunicipalitiesareimposingchargesandfinesonpolluterswhichareunlimited.

Inenvironmentalsituationsclaimsof‘ignorance’arenolongeradefence,chargesandfineswillbeimposedpluscostsoneverypolluter.Simpleactionssuchasmakingsuresinkfiltersaresuppliedandused,oilandoilbasedproductsarenotdisposedofintowasteoutlets,sanitizersarenotputintosinksortoiletoutlets,handwashisdonebythreestageprocess, i.e. soap wash, dry and sanities.

Section 3 Water Supply & Drainage

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Simply if oils and sanitizers are excluded from drainage many problems will not require remediation.Amanagementplanfordrainageandgreasetrapsincludingarecordcardtoshowcleaningscheduleshouldbeincluded in any kitchen risk analysis.

In accordance with current guidance from UK Water Companies, Dishwashers and waste disposal units should notbeconnectedtogreaseseparators.

Grease Traps

SurfacemountedGreaseInterceptorsshouldbepositionedtoallowaccessformaintenance(andcleaning).Unitsarefit-tedtogreaseproducingequipmentwithinthekitchentostopFOG(Food,oilandgrease)fromenteringdrainagesystem.Interceptorsshouldbepositionedatleast50mmfromwallsforcleaning.A5ampfusedspurisrequiredforinstallationofthedosingsystem.ElectricalcontractorsshouldbeconsultedtodeterminewhetherthisshouldbeIPrated.Althoughitiscommonplacetofitinterceptorsbeneathasinkdrainer,theycanbeinstalledinanypositiononthepiperunwherespaceisavailable,(Arecommendedlidclearanceofaround250mmisrequiredtoallowaccessformaintenance).Kitchendesignersshouldrecognizetheneedtospecifyfabricationdesigntoaccommodatethetrapsparticularlyinundersinklocationsi.e.noundershelfandtiebarstoextremitieswheredimensionsarecritical.

Bioremediation

Whereverpractical,dosingshouldbefittedattheheadofthedrainagerun.Tubingconnectionisintothetopofthewastepipeusingsuppliedfittings.Theentrypointisviapipeworkwithdirectaccesstotheinterceptor.Whendosinganoutdoortrap,entrypointshouldbewithinthekitchenattheheadofthedrainagerun.

Design Considerations

•Scrapping/Pre-rinsespraysinks(highestvolumeofwastefromthissink).•Panwash/Dirtysinkproducesfood,oil&greasewaste.•SteamingandCombiOvens.SOGTinterceptororanundergroundgrease(UG)trapshouldbeinstallede.g.20gridwastepipeistoolowforanabovegroundgreasetrap.•Butchersprepsinksproducegrease.•Bakerssink(wherepiesorsavoriesareprepared,theyproducefood,oil&grease).•Sinkswherecream,milk,mayonnaiseorsaladdressingsareused,theyproducefood&oil.•Thebiggerthebetter(largertrap=largersettlementarea,morewater,oxygenandsurfaceareaforbiologicalactiontooccur).•Biologicalvs.Traditional(Smallvs.Largecapacity).•Biologicalvs.Mechanical(Sustainablevs.Replaceable).•FloorGullies/ChannelsconnectedtoUGgreasetrap(Wastepipesfromsinksshouldbeconnectedtosealeddrainageconnectionswithroddingaccess).•PotatoPeelers(starch,gritandskins).•Wastedisposalunitsshouldbepipedintoawastefoodcollector.Thisshouldnotbeintroducedintothe drainage system.•BrattPans/TiltingKettles.TheseproduceF.O.G(GulliesshouldbeconnectedtoanUGtrap)•Washhandbasins(useplainsoapandseparatesanitizerforhands).•WokRanges(Theyproduceoilandfoodwastetrappedatsource).•YardGullies(GreaseManagementSystem(GMS)requiredifareaisusedtowashdownequipment).•SinkFilters(reduceeffluentintrapsandpipes).•ForUGunits,coverloadings/floorcoveringsmustbeconsidered.•HACCP-Regulation(EC)No.852/2004onthehygieneoffoodstuffs.

Section 3 Water Supply & Drainage

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Section 3 Sizing of Grease Traps

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Dishwashers should not be connected through traps, as this can result in an emulsification of contents reducing efficiency. Interceptors installed outside or underground should be specified as one size larger than the AG equivalent (to allow for an extended maintenance period).

ThecalculationofGrease/OilInterceptorsizeisnotanexactscience,factorstoaccountforare:typeofpremises,cleaningregime,stafftraining,frequencyofcleaning,availablespaceforfitting,placeoftrape.gabovefloor/belowfloorinsidekitch-en outside kitchen. Supplier should have experience to advise on trap sizing, training & cleaning frequency.

Sizing Biological Grease Separators In accordance with current guidance from Water Authorities, dishwashersandwastedisposalunitsshouldnotbeconnectedtogrease separators. Sizing for Above Ground Grease TrapsPlease refer to the chart on the relevant page for the grease trap sizes.To determine the size of grease trap, calculate the volume ofwater,dividebythedischargetime(2minutes).

Example:

Sink Size 2x400x400x(250),overflowheight(OH)is220.Volumeis2x400x400x220=70.4L

Sink Size lx500x400x(300),overflowheight(OH)is220.Volumeis31x500x400x220=44.0LTotalVolume=114.40L

Size of Grease Trap114.4Ldividedbydischargetime(2Min)=57.2LUseAG2(115L)forAboveGroundSeries.Lcubicm=1tonne-1000L

Alulinewillprovideyouwithcompletespecificationforyourconsideration.Ideallythisshouldbeimplementedatdesignstagewhethernewbuildorretro-fit.

Constructingtailormadesolutions.Ourservicesareentirelybespokeandbasedonindividualdeliveryplansforeachpremisesorproject,weproducesitesurveystoensureyourunderstanding.

Theactual loading shouldbeassumed tobe60%of theabovevalue,asmostappliancesandfixturesarenotfilledtothebrim.Inmanycases,thesefixturesarefilledtolessthan60%ofthecapacity, especially when water is at premium. Most large businesses reduce water consumption to attain economicandenvironmentalbenefitsandreducecarbonfootprint. Sizing for Under Ground Grease Traps We use the same methodology for the Under Ground series (howeverasaruleofthumb)weadviseusingonesizelargerto reduce the cleaning regime. When specifying Under Ground Traps, the T-Dimension or invert level,itisimportanttoensurethatthelidisatafinishedlevelandincrementcostcanbecalculatedforbillofquantities. Access to final position for cleaning is important during thespecificationstage.

Flow Rating

A2minutedrainageperiodisacceptableforcommercialfittingstofullydischarge.Tocalculatetheflowrating,simplydividethelitrecapacityofthekitchenfixturesandequipmentby2(drainageperiod)togiveflowratinginlitres/minutethendivideby60tocalculatelitres/second.

Example:

59.4 litresmultipliedby0.60 to give actual loading for a singlecateringsink=35.64litres.Thisisthendividedby2=17.83litresper minute or 0.297 litre per second.

Under European Legislation, dishwashers are assumed to have flowrating2litres/second.

SinkSize(mm) OverflowHeight(OH)

Volume(Ltrs)

600 x 450 x 300 x 220 59.4

500 x 400 x 300 x 220 44

500 x 400 x 250 x 220 44

400 x 400 x 300 x 220 35.2

400 x 400 x 250 x 220 35.2

200 x 200 x 110 x 65 2.6

The calculation of Grease/Oil Interceptor size is not a science. Factors to account for are:

•Typepremises.•Cleaningregime.•Stafftraining.•Frequencyofcleaning.•Availablespaceforfitting.•Placingoftrape.g.abovefloor/belowfloor,insidekitchen-outsidekitchen.

Suppliersshouldhaveexperiencetoadviseontrapsizing,training&cleaningfrequency.Theactualloadingshouldbeassumedtobe60%oftheabovevalue,asmostappliancesandfixturesarenotfilledtothebrim.Inmanycases,thesefixturesarefilledtolessthan60%ofthecapacity,especiallywhenwaterisatpremium.Mostlargebusinessesreducedwaterconsumptiontoattaineconomicandenvironmentalbenefitsandreducedcarbonfootprint.

Inaddition,itisextremelyrarethatallfixturesandequipmentaredischargesimultaneously.

Flow Rating

Atwominutedrainageperiodisacceptableforcommercialfittingstofullydischarge.Tocalculatetheflowrating,simplydividethelitrecapacityofthekitchenfixturesandequipmentby2(drainageperiod)togiveflowratinginlitresperminutethendivideby60tocalculatelitrespersecond.

Example:59.4litresmultipliedby0.60togiveactualloadingforasinglecateringsink=35.64litresThisisthendividedby2=17.83litresperminuteor0.297litrespersecond.UnderEuropeanlegislation,dishwashersareassumedtohaveflowrating2litrespersecond(sourceBSEN1825-2)

Bioremediation

AsstatedinthePDIGuide“Theconceptofbioremediationissound,trapgreasesanddigeststhemintheinterceptortoconvertthegreasepermanentlyintotheby-productsofdigestion”.

Thenormalby-productsofbioremediationarecarbondioxideandwater,producedasthebacteriainAluzymedosingsystemsbegintodegradethedigestiblewastematerials.

Thisisanimportantconsiderationwhensizinggreaseseparators,astheprocessallowssmallerunitstobeinstalled.Evenwhentheseparatorisoverloaded,theorganicmaterialcontainedwithiniscoatedbyabiofilm.Whentheseorganicmaterialspassthroughthegreaseseparatortheyarecontinuallybeingdegradedastheyflowaway.

Anotherkeybenefitofbioremediationisthattheprocessintroducesbacteriaintopipesystemsallowingadditionaltreatmenttotakeplace.Thebacteriacollectonanywetsurfaceandmultiply,resultinginabiofilmbeingcreatedwithin the pipes.

Selection of the Nominal Size

For more guidance and information on selecting the nominal size for a grease separator and formula for calculating therequiredsize,pleaserefertoourcalculationfornominalsizehandbookattached.


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Section 3 Grease Trap Comparative Analysis

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Aluline Grease Trap Advantages Mechanical Devices Disadvantages

4

Aluline Interceptors are environmentally designed to prevent and stop excess food, oil and grease from entering the drain system through it’s waste treatment at source technology. 7

Grease Guardian or Pelican series contain electronic moving parts.

4

Biological treatment of retained food, oil and grease in an interceptor will reduce the frequency of maintenance.

7

Theaccessintotheunitscanberestrictedforstafftocleanthem.Theycausedifficultytodislodge,i.etheunitsfillupwith solids and cause mechanical parts to seize and fail. After theequipmentfailstheelectronicmotorandPCBboardburnsoutandcancausedamagetotheproperty.

4

TheAluzyme’sbiologicalactionactivatesthebacteriatobedegradeanddigestthewasteintoH2OandCo2inthetank and enhances the performance of pipeline systems and waste treatment tanks.

7

The automatic grease convertors do not adopt the technologyofbioremediation.

4

Pipelines running several meters from the food production area to the main manhole or the pumping stationsremaincleanandtroublefree. 7

AnautomaticGreaseTrapmustbesizedasaconventionaltrap. The cleaning cycle only works once per day.

4

Easytomaintainandcleanbyclient/serviceengineerasper Aluline service training provided during installation and routine follow ups. 7

It is uncertain if these traps are pressure tested on site. if it appearsthattheyarenotairtightthentheyshouldnotbeused inside a kitchen.

4

Stainless steel and air tight design plus the training given on hygieneallowsalulinetrapstobefittedinthewashupareasinkitchenandtheundergroundfloormountedgreasetrapsdonotoverflow.

7

Thedailycleaning(removingbasket,employingandreplacing)ifthisiscarriedoutbyuntrainedstaffitmayhavehealth implications.

4

Aluline cleaning systems allows the solid waste from these trapstobeplacedinclientswasteskips

7

The inclusion of electricity in a wet environment area where staffhavelittletimetobecareful,suchaswashupareainkitchenishighlyquestionable.

4

Aluline advises clients on contractors who collect waste oils.

7

Has this type of unit any approval or acceptance from food and hygiene departments?

4

Alulinetrapscanbeeasilyrelocatedevenifitisfloormountedinthebasement.

7

The cleaning of these traps to remove accumulated waste notaddressedbythewheelcanprovedifficultandisolation of electricity is a must.

4

Alulinegreasetrapsareeasytoinstallandbecomestheresponsibilityofthekitchenchefandtheservicemanagerwho are actually generating the waste. 7

Theuseofanoutsidetub/containermaynotgiveanyairseal and gas etc. can escape into the kitchen.

4

Alulinetrapscansbeopenedforinspectionandcleaningatanytimebyremovingtheclipsasperthetrainingprovided. 7

Anyblockageorstoppageintheoutletcancausefloodingasunit is not air sealed.

4

Alulinetrapscanbeopenedforinspectionandcleaningatanytimebyremovingtheclipsasperthetrainingprovided.

7

Thequalityorsealetc.totheseunitsleavesalottobedesired.

7

If your company is interested in the type of unit, we advise a visittoanestablishmentwheretheunithasoperatedover18 months. New units do not give a fair representation in factthisshouldbetheadviceforallunitsnomatterwhichmanufacturer or what type of unit.


Premises Operation Minimum Requirements

Auto Repairs Oil, Grease & Petrol Fit Oil Separators

Plant Operator Hydrocarbons,Metals,SuspendedSolids Fit Oil Separators

Bakery Suspended Solids, Grease & Oil Fat Oil Separators

Beauty/SpasNailBoutiques Suspended Solids Wax, Oil, Mud Pack, Hair Fit Filter system to suit operation

Building Construction Sites Cement, Oils, Paints, Chemicals Check with drainage authorities any entry to sewersystemshouldhaveatrapfitted.

Cafe Sugar, Mayonnaise, Coffee Grounds, Milk, cream,butter,chemicals

Fit Grease Traps

Chicken/Fresh Suspended Solids, Gut Grease, Blood Fit Grease Traps

Cutting Preparation Suspended Solids, Grease, Oil Finings Fit Grease Traps

Coffee Shop Coffee Grounds, Milk, Sugar, Cream Syrups Fit Grease Traps

Catering Kitchen Suspended Solids, Oil, Grease, Chemicals Fit Grease Traps

Community Facilities Suspended Solids, Grease & Oil Fit Grease Traps

Ceramics/Plaster Suspended Solids Fit Filter System

Delicatessen Suspended Solids, Grease, Mayonnaise, Butter Fit Grease Traps

Dentists T.B.A Check withDrainage/HealthAuthority

Doughnuts Grease, Sugar, Oil Fit Grease Traps

Dry Cleaners Solvents etc. Check withDrainage/HealthAuthority

Fish Retail Suspended Solids, Scales, Fish Gut Dry Filter System

Fish Restaurant Suspended Solids,Grease, Oils Fit Grease Traps

Fast Food Suspended Solids, Grease, Oil Fining’s, Chemicals Fit Grease Traps

Florist SuspendedSolids,Herbicides Check withDrainage/HealthAuthority

Hotels Suspended Solids, Sauces, Mayonnaise, Butters,Oil, Grease, Chemicals

Fit Grease Traps

Ice Cream Parlour Suspended Solids, Milk, Fats, Oils, Cream Fit Grease Traps

GarbageAreas Suspended Solids, Oils, Chemicals Check Disposal System Fit Grease Trap

Glass Finishing GroundGlass/Chemicals Fit Filter System

Hair Dressing Oil, Hair Fit Filter System

Hospital Suspended Solids Check withDrainage/HealthAuthority

Jewellery Plating, Cutting, Grinding, Suspended Solids Check withDrainage/HealthAuthority

Laboratory Chemicals Auto Clave Balancing Tank, check with Drainage/HealthAuthority

Laundry BOD,suspendedsolids(int.)Ammonia,Boronetc. Lint Separator, check with Drainage Authorities

Medical Centre SuspendedSolids,X-ray(slider) Check withDrainage/HealthAuthority

Morgue Check withDrainage/HealthAuthority

NightClubswithFood Chemicals, Suspended Solids, Oil, Grease

Nursing Home Chemical, Suspended Solids Fit Authorised Grease Trap

Options(GrindingGlass) Ground Glass, Suspended Solids Fit Air Filter

Shell Fish Factory Suspended Solids, Fish Gut, Shell Fit Filter System to remove Suspended Solids

Photographic Processing Suspended Solids, Chemicals Check with Drainage Authorities

Pizza Shop Suspended Solids, Oils, Mayonnaise, Sauce Fit Grease Traps

Sandwich Shop Suspended Solids, Mayonnaise, Butters Fit Grease Traps

ServiceStation(food) See Auto Repair, SuspendedSolids,Coffee,Sugar,Juices Fit Grease Traps

Ship to Shore Sanitary&Kitchenwasteshouldbehandledseparately Check withDrainage/HealthAuthority

Swimming Pool SuspendedSolids/Chemicals Silt Tank, Check with Drainage Authorities

VehicleWashing Silt, Oil, Chemicals Fit Oil Separators

Veterinary Suspended Solids, Animal Feeces Check withDrainage/HealthAuthority

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Pipe Work Guidance

p17

1.Alutrapfittedabovefloorexcludestherequirementtocutthefloorslabs.Cuttingslabsmayaffecttheintegrityofsteelreinforcement/waterproofsealsandhangingtrapscaninterruptservicesinunitsituatedbelowslab.

2.UsinganabovefloorAlutrapreducesblockagesinpipesembeddedinconcreteorinceilingvoids.

3.Alutrapisairsealed.(Ifmainpipesareproperlyventedtrapsrequirenoventing).

4. At design stage care taken to position sinks and pipe work from the equipment requiring trapping may reduce the numberofAlutrapsrequired.Aspaceofatleast250mmisrequiredabovethelidtofacilitatecleaning.SinkU-bendsmustnottouchthegreasetraplidsandaminimumspaceof35mmisrequiredbetweentheU-trapandthelid.

Pipe Work

1.Mainpipeworkwithincommercialkitchensshouldbe50mm.2.Shortconnectionsofappliancestomainpipeworkshouldbe40mm.3.Washhandbasinconnectionstopipesshouldbe32mm.4.Pipeworkshouldbeaminimumof20mmfromwalltoallowforclearingunderneath.5.Allpiperunsshouldbeprovidedwithadequatesupports.6.Thefittingofconcealedpipesinblockwalls“bychasingmethod”mustbeauthorizedbyastructuralengineerto ensure wall integrity.7.Extremecareshouldbetakentoensurewallsarenotchasedtoodeeplyoneachsidetoacceptservices.8.Connectionsfromfittingsshouldenterwallsbetween200mm-250mmfromfinishedfloorlevel.

Floor Gullies/ Channels

Inthekitchenitisrecommendedthatthesetobekepttoaminimumandwhereverpossibleshouldhaveasealedlid.

Channelsaresuitableforlargecommercialorindustrialkitchenswherewashdowniscarriedoutusinghosesorlargequantitiesofwater.Asapotentialhealthhazardifnotproperlymaintained,gulliesandchannelsshouldbegivencarefulconsideration in terms of their requirements.

Sinks

1.Wastepipesfromsinks/greasetrapsshouldnotdischargeintofloorgullies.2.Werecommendthattheyareconnectedtoaroddablestubstack.3.Pipeworkshouldbemanufacturedtoarecognizedstandardrequiredforthejobinhandandwhenlaidinthefloors,wallsorunderconcretefloorslabs.Careshouldbetakentoensurethatroddingpointsareinstalledincaseofblockagesinlocationswhereaccessisdifficult.4.P-trapsshouldbeinstalledunderallitemsofequipmentconnectedtothedrainstopreventmalodorsbacking up through pipes.

Appliances

Dish/GlassWashers, ensure an adequate trap isfittedbetweenmachine&waste-pipe inlet toensure anodour /airbornebacteriaseal,Icemakers,Combinationovens,steamersmustallhaveanairbraketopreventwastewater(bacteria)enteringthechambers.

Pipe Work Guidance

p18

Pipes through a Structural Floor

Structuralengineermustgivepermissionforanyfloorpenetrations.Inmulti-storyblocksthecivilauthorityregulationsmustbeconsultedonFireRegulation/Protection.Pipestakenthroughslabsmayrequirepuddleflangestopreventwaterpenetrationthroughtheslab.Pipespassingunderfloorsmusthavealongradiusbendfittedtoassistcleaning(ifitisrequired).Ifgullyisfittedthroughthefloor,trapmustgiveaccessforrodcleaningofthelongradiusbendandpiperun.

Guidance for Underground Pipe Work

Guidance for underground pipe work

1.Itisimportanttospecify&ensurefittingofpipeworktoarecognizedstandard.2.Itissensibletoensurecontractor/subcontractorunderstandsregulation&yourinstallationrequirements.3.Atdesignstageensureaccesspointswillbeaccessibleinthefinishedproject&thattheseareactuallyfitted.4.Maintenanceondrainagesystemislargepartofbudget.Design/installationcouldsubstantiallyreducethiscost.5.Design/installationshouldensurebends/tees/junctionshavelongradiusorsweptfeaturetoalloweasyaccessforrodding/cleaningjettingfunction.Thiswillalsoreducepotentialforblockage.

Gullies

Gulliesareheightadjustableforeaseofinstallationandincorporateremovablegratings,odortraps,roddingportsandwastebaskets,allowingfullboreaccess.Outletsareverticalorhorizontal.Gulliesare ideal for Commercial and Industrial Kitchens, Food & Beverage, Chemical, Pharmaceutical Industries, Building Exteriors, Parking Buildings, Underground Garages, etc.

x x x

Screed Screed

StructuralSlab

StructuralSlab

StructuralSlab

PuddleFlange

PuddleFlange

Screed

PuddleFlange

PuddleFlange

PuddleFlange

Odour Trap Odour Trap

Gratings

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Gratings

Gratingsareespeciallysuitable fordirectdischarge fromequipments.The freedrainagearea isupto90%of thesurfaceareaachievingavirtuallyanti-splashinstallation.SmoothMeshisavailableinstandardandheavydutyforusein general drainage and fork lift area, Non-Slip Mesh is used in kitchen and production areas, Perforated is used in productionandbarefootpedestrianareas.

Channels

DrainageChannelsaredesignedwithabuiltinfallandarangeofedgeprofilestoaccommodatealltypesoffloorfinishes.Anchorsandlevelingboltsareprovidedtoeaseinstallations.Lengthsareonlylimitedbytransportationlogistics.

Theexcellentsmoothsurfacefinishofstainlesssteelprovidesaselfcleansingvelocityforliquidsatveryshallowgradients.Theself-cleansingvelocityis0.75m/s.Velocitiesbelowthisfigurerequiremanualflushing.

Widthsofchannelswilldependonthesplashareabelowdischargingequipmentorappliancesandshouldbeaminimum200mm wide overall for wash down installations.

Thedischargeofthedrainagechannelisrelativetotheflowratecapacityoftheoutletgully.Dischargecapacitiesofbothchannelandgullywillbereducedwhenconveyingwater-bornesolids.Typicalgradientsare1%.(1:100)forliquidwaste,2%(1:50)forwater-bornesolids.

Thechanneledgedetailwilldependonthefloorfinish,examplesbeingtile,resinorvinyl.Channelscanbedesignedto provide vinyl one side and resin or tile the other.

Forapplicationswhereheavyloadsand/orthermalshockareanticipated,anexpansionframearoundtheperimeteris recommended.

Theexpansionframeissuppliedfactorytackweldedtoallprofiles.

•AllourdrainageproductsaremanufacturedinStainlessSteelGrade304or316.•Canbemadetosuitsiterequirements.•BackandSideInletscanbefittedtoclientsrequirements.•Fallscanbeincorporatedtosuitfloordepth.•Channelsover2.5mwillhaveflangedjoints.•Filterbasketsarerecommendedforalloutlets.•WemanufactureanddesignGulliesandChannelsforcommercialkitchens.•AllGulliesandChannelsaredesignedtoalloweasyroddingaccessandmaintenanceonceinstalled.•Gratingsforchannelsaremadetofitdishwashersforcleaningandsterilizing.•WidthStandard150mm,200mm,300mm,400mm,450mm.

Note:PlumbinganddrainagemustcomplywithBS6700:2006+A1:2009.

Legislation

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Aluline recommends the use of grease separators to ensure that all your clients are fully compliant with current environmental legislation. According to Part H of the current edition of the Building Regulations in England and Wales, Drainage serving kitchens in commercial hot food premises should be fittedwith a grease separatorcomplying with BS EN1825-1, and designed in accordance with BS EN1825-2, or other effective means of grease removal.

TheScottishBuildingStandardsareevenmoreexplicitintheircallforseparators,stating:

Where a discharge into a drainage system contains oil, fat, grease or volatile substances, for example form a commercial kitchen, there should be facilities for the separation and removal of such substances. Separator systems are used in a wide variety of situations to fulfill a number of different requirements. It is important to establish why a separator system is needed and what specific function it is expected to fulfill before selecting the appropriate size and type of installation.

Separators should be constructed and installed in accordance with the following draft European standards.

A: BS EN 858-1: 2002 for light liquids such as oil or petrolB: BS EN 1825-2: 2002 for fat or grease

Companies who advocate dosing systems without grease traps are effectively encouraging non-compliance in relation to theseregulations.Theyarguethatbydosingthedrains,clientsareadopting“othereffectivemeansofgreaseremoval”.Inadditiontotheregulationscurrentlyinplace,ifacommercialkitchenhasablockageorpollutesthedrainagesystem,therelevantauthorities’havethepowertofinetherestaurantoperators(andinextremecasestheindividualsworkingwith-inthekitchens).Ifthatsitehasnogreaseseparatorinstalled,thentheyhavelittleornoprotectionfromthesefinesandcharges(whichcanvaryfromhundredstothousandsofpoundsdependingontheseverityofthepollution.Thereforeaninstalled and well maintained grease separator indicates to authorities that operators have used due diligence.

In Practice

Theideaofbiologicaldosingorbioremediationissound,andintheoryitcanbearguedtobeaneffectivesolution,however in practice, it has its limitations.In our experience, dosing as a stand alone solution does not work effectively. This is due to the amounts of food wastedischargedintothedrainagesystem,whichthebacteriacannotdigestinthetimeallowed.Someofthetypesorstrainsofbacteriausedinbiologicaldraindosingsolutionscandigestfoodparticles,buttheytakeaverylongtimeto do so, and require the right conditions.

Asecond,significantlimitationofdosingonlysystemsisthatthebacterialliquidsthattheydispenseintothedrainsflowsdirectlyintothesewersystem.Thismeansthatthereisnothingbywayofretentiontimetoallowthebacteriato colonize within pipes. By the time the dosing liquids have reached a point within the drainage system where they cantreataretainedamountofwater(e.g.inamanholeorpumpingstation,otherpipeshavebranchedintothedrainrun,andmoreoftenthannottransportantibacterialchemicalsfromhandwashbasins,orharshchemicalsfromfloorgullieswithinthewastewater.Thesechemicalsthenkillorretardthebacteriamakingthemmuchlessefficient.

Intruth,biologicaldraindosingwouldbean“effectivemeansofgreaseremoval”ifnofoodwastewasdischargedintothedrainagesystem(whichisunrealistic)andifnoanti-bacterialchemicalswerepresentinthedrainstokillthemofforslowtheiraction(i.e.allstaffincateringestablishmentsadopteddrycleaningratherthanwetcleaningandonlyusedpapertowelswhencleaningandsanitizing,ratherthanclothswhicharethenrinsedinsinks).Intherealworldthisisdifficulttoenforce.

Youandyourclientsareawareoftheproblemsalso.FollowingrecentproblemsatasiteintheWestMidlandswherenogreasetrapwasinstalled,foodwaste,oilandgrease(FOG)collectedinthedrains(alongwithsomebuildingde-bris)andcausedthedrainstoblock,resultingintheneedtodigoutthedrainsatlargeexpense.Whileagreasetrapwouldnothavemadeanydifferenceinrespectofthebuilders’wastewithinthedrains,itmostcertainlywouldhaveassistedinthiscasebypreventingthequantitiesofFOGfromcollectinginthepipes.

Oneofthebiggestproblemsfacingoperatorsisthattheperformanceofadosingsystemcannotbemeasuredimmediately.Forexample,itmaytakeaveryhighvolumesite6monthstoblockthedrains,whileinothersitesitcould take three times as long. This can give the impression that a system is working when in fact it is not.

Legislation Grease Separator Systems

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DrainageservingkitchensincommercialhotfoodpremisesshouldbefittedwithagreaseseparatorcomplyingwithBSEN1825-1:2004anddesignedinaccordancewithBSEN1825-2:2002orothereffectivemeansofgreaseremoval.

Thereasonsthatgreaseseparatorsystemshavebeenhistoricallyeffectivearesimple.

•Theseparatorcatchesfoodwasteandretainsoilandgreasefortreatment,removalanddisposal.•Duetoitslocationwithinthepipesystem,thegreasetrappresentsabodyofwatertobedosed,allowretentiontimeforthebacteriatodigestthefatandgrease.Also,iflocatedcorrectly,thegreasetrapcanbeinstalledinapositionthatpreventslargequantitiesofantibacterialorotherharshchemicalsfromaffectingit(e.g.wherehandwashbasinsanddishwasherscanbeallowedtobypassthetraps).

Inessenceagreasetrapallowsproblemareas(washupsinks,combiovensetc)tobeisolatedanddealtwith,allwhilstbeingaboveground,sothatifablockageweretooccur,itisinaneasilyaccessibleareaandcanbedealtwithrelatively cheaply and quickly.

Weunderstandthatoperatorscanbecriticalofgreasetraps,findingthemunpleasanttomaintainattimes.Themostfrequentcomplaintwegetisthattheysmellorbecomeblocked,andbothoftheseproblemsaredirectlyattributedtoexcessfoodwastebeingcollectedwithinthem.Theeasiestthingtodoistoaskyourself,“Ifthegreasetrapwasnot present, where would all of that food waste go?”

Biological Grease Traps

Thereasonsfordosinggreasetrapsarethreefold:

•Usingbacteriainthegreasetrapsassiststhebreakdownoffatandgreasemakingthetrapmoreefficient,but this is due to the retention time that the trap affords.•Asthegreasetrapismademoreeffectivebyincludingdosing,asmallerunitcanbeusedwhenusingdosing(Alubio-Traps)whichallowscompliancewithBSEN1825-1:2004.•Thebacteriawithinthegreasetraphelpstopreventthebuildupofanaerobicbacteria(whichcreatethefoulestodours)resultinginanimprovementintheodourswhenmaintenanceisrequiredandthelidsor covers are removed.

Benefits of Aluline Equipment and Service

AllAlutrapabovegroundgreaseseparatorsaremanufacturedanddesignedtobeairtight,topreventairbornebacteriaescapingfromthetrap.Thisensuresthat(solongasthesealsareintact)noodoursorwatercanescapeintothekitchen.Our separators are made this way to satisfy environmental health concerns and prevent any contamination within the kitchens.

Aluline’s policy of training staff when commissioning new installations ensures that operators not only know how to maintaintheequipment,butalsohowtoassesswhenitisrequired.Ourengineersthenprovideareactiveservicetosupplementthistraining.Also,byprovidingahealth&safetyapprovedcleaningkit,staffcanmaintaintheequipmentin a safe manner and prevent cross contamination within the kitchen.

Section 4 Fixtures, Fittings and Equipment

p22

This sectioncovers the installation,material,maintenanceandcleaningoffixtures,fittingsandequipment incommercial kitchens.

Commercialkitchensarerequiredtoprovideadequatefixtures,fittingsandequipmentnecessaryfortheproductionofsafeandsuitablefood.Fixtures,fittingsandequipmentcoveredinthissectionarethoseitemsinstalledaspartofthefitout,suchasrefrigerators,preparationbenches,displayunitsandshelving,andnotlooseutensilssuchaschoppingboards,cutleryormixingbowls.

Glossary

Installation:Theprocessofbeingplacedinpositionforserviceoruse.Process:Anactivityofpreparingfoodforpublicconsumption.

4.1 General Requirements

Fixtures,fittingsandequipmentwithinafoodpremisesmustbeadequateforthesafeproductionoffood.AllsurfacesmustbenonPorous,i.e.stainlesssteel(Woodisnottobeusedinthekitchenarea).

Theoperationsofakitchenrequireadequatefixtures,fittingsandequipmentforthefollowingoperations:

•Servingfood.•Packaging.•Transporting.•Storingrecalledfoodorfoodfordisposal. Dependingontheactivitiesundertaken,thefollowingequipmentmayberequired:

•Coolroomsandrefrigeratorsforchilledstorage.•Benchesandworktablesforpreparation.•Ovens,stovesandothersuchequipmentforcooking.•Hotboxesandovenscapableofholdingfoodat63ºCorabove(hothold).•Displayunitsthatprotectfoodfromcontaminationandholdthefoodat63ºCorabove(hotdisplay).•Displayunitsthatprotectfoodfromcontaminationandholdthefoodat5ºCorbelow(chilleddisplay).•Blastchillersthatcanreducethetemperatureasspecifiedinlocalregulations.•PortableRCDs(ifelectricitysupplyformovableequipmentisnotRCDprotected).

4.2 Installation

Allequipmentshouldbeinstalledsothatitcanbeeasilycleanedandpreventanyfoodspillagebuildingupbehindor underneath the equipment.

Allequipmentshouldbe:

•Beeasilymovedforcleaning.•Builtagainstthewallorotherequipmentandthejointsmustbesealed.Wherefeasible,allequipmentonlockablecastorswithsignificantlengthofgashosestoallowequipmenttobemovedtoenabletocleanandserviceeasily.(e.g.Combi’shaveawastepipe,toallowtheliningupofthewastefromthecombioventohelpensurenospillageontheflooraftercleaning.Asimplesolutionwouldbeatundishsecuredonalocatingbracketfixedtothefloor).•Twocastorslocatedatthebackwithlegsatthefront.Note:Theweightoftheunitmustbeconsideredfor Health & Safety.

EquipmentconnectedbyafusedspurisexemptfromPATtesting.

Section 4 Fixtures, Fittings and Equipment Section 4 Fixtures, Fittings and Equipment

p23

4.3 Specific Requirements

•Refrigeratedcounters;(eitheranumberofrefrigeratedcabinetsoraframeinonepiece),arerequiredto have one continuous topofstainlesssteel,freeofopenorroughjoints,cracksandcrevicesandroughsurfaces.•Countersandbars,fooddisplayunits,windowdisplaysandself-servicedisplaycabinetsandbain-mariearerequiredtohaveallsurfaces(includinginternalsurfaces)smooth,durable,imperviousandfreefromcracks, crevices and cavities.•Cupboardsandcabinetsshouldhaveasmooth,washablefinishforallsurfacesandremovableshelves.•Countersforfoodselectionand/orpreparationbythecustomerarerequiredtohaveaprotectivebarriertoprovideaphysicalbarrierbetweenthecustomerandthefood,e.g.sneezeguards.•Dumbwaiter(foodconveyors)musthaveasmoothimpervioussurface,freeofcrevicesandopenjoints.Verticalconveyorsmusthavethewalloftheshaftmadefromasmoothmaterial,freeofanycrevicesorcracks.Accessmustbeprovidedforcleaning.

4.4 Materials

Surfacesincontactwithfoodmustbeeasilycleaned,andnotbeabletoabsorbgrease,foodparticlesorwater.Stainlesssteel:suitableindirectcontactwithfood.Itisdurableandcanwithstandchemicals.Itisavailableinvariousgradeswhichshouldbechosenbasedontheapplication.

Stainless SteelShouldonlybeusedinakitchenwith304gradesteel.Thishasalowcontentofironandwillnotrust.

Iron and mild steelShouldnotbeusedinthekitchen.

Timber productsTimbershouldnotbeusedinakitchen.Onlyinspecificcircumstancessuchasbutcheryandsomebread-makingoperationsshouldtimberbeused.

PlasticsPlasticlaminateandsolidsurfacematerialsaresuitablesurfacesforfoodpreparation.Allsurfaceshouldbenonporoustoensureeaseofcleaning.Note;whensurfacebecomesscoredorscratcheditshouldbereplaced.

4.5 Cleaning, Sanitising and Maintenance

Afoodbusinessmustmaintainfoodpremisestoahighstandardofcleanlinessandensurethereisnoaccumulationoffoodwaste,dirt,greaseorothervisiblematter.

A clean and sanitary condition is the condition of a surface or utensil where it is clean, and has undergone application ofheatandchemicalsorotherprocesses,sothatthenumberofmicro-organismsonthesurfaceorutensilhasbeenreduced to a level that does not compromise the safety of the food with which it may come into contact and does not permitthetransmissionofinfectiousdisease.Sanitisershouldonlybeusedwithadrywipeandsprayandshouldneverbeputdownthesinkordrains.

4.5.1 Cleaning and Sanitising of Equipment

Afoodbusinessisrequiredtosanitiseeatinganddrinkingutensilsandfoodcontactsurfacesthatarelikelytocontaminate food. A food premises is required to provide equipment for cleaning and sanitising.

Allfoodpremisesrequirethateachprepareashouldhavetheirowndedicatedsinksandwashhandbasinstopreventcrosscontamination.Washhandbasinsshouldbeseparatewithaphysical/airgaptostopcrosscontamination.

Section 4 Fixtures, Fittings and Equipment

p24

Walls & Floors

Practiceof sanitisingwalls can causeproblemswhendisposingof the sanitizer as this shouldnever go into thedrainage.Ithasbeendocumentedthatbacteriawithinthreehourshavere-colonizedontheseareaswhereorganicmatterhasnotbeencleaned.Theuseofsanitiserisnotrecommendedasapropercleaningmethod,theareasshouldbethoroughlycleaned,removingallorganicmatter.Usingsanitizertocleanfloorsandwallsisnotrecommended.Acleaningagentthatwillremoveallorganicmatterfromwallsandfloorsleavingacleansurfacewithnomaterialforgermstore-colonizeisadvised(newproductsactuallycontainingbacteriaarebeingdesignedforthispurpose).Sanitiser solution should never enter the drainage network.

Touch Surfaces

Alltouchsurfacese.g.handles,tabletops,doors,washhandbasins,switches,cutleryboardsshouldbesanitisedusingaspraybottleandpapertowels,againtheremovalofallorganicmatterisparamount.Sanitisingofallknives,cooking,drinkingutensilsshouldbedoneinthedishwasher/glasswasher.Itisadvisablethatallstaffhavetheirownplates,mugs,cups,etc,tohelpwithpreventingcrosscontamination.Anycommonutensilsshouldbesanitisedaftereachperson uses it.

Wash Hand Basins – WHB

Washhandbasinsshouldbepositionedinsuchawaythatthewaterdropletsfromhandwashing,donotcomeincontactwithsurroundingworksurfacesoranyplaceswheregramnegativebacteriacancolonize.Thepracticeofcleanwashhandbasinsisacauseforconcern.ThenewespeciallydesignedQuadwashunitswillensureproperhandcleaning/sanitisingandgreatlyreducetheriskofinfection.Itwillalsoreducewateruse,thecostofpapertowelsanddisposal.Theseunitscanbefittedwithmonitorstoteachhandwashingpractice.Theycanalsobefittedwithacontrolunitrecordinghandwashusageofindividualstaff.Therecordingsystemcanbesettoregistertoiletvisitsandcanbeusedtotrackstaffmovementsthroughoutthefacility,especiallyinfoodproductionfacilities,hospitals,etc.

Legionella

Propercleaningofwetareaswillreducetheriskofwaterbornediseasese.g.Legionella,E.coliandothernastyinfectionswhichcanbetransmittedthroughwater.

4.5.2 Sinks

Sinksshouldbeprovidedtosuitthelargestpieceofequipmentbeingcleaned.Largerpotsinksmayberequiredtosupplement standard sinks.

Sinksarerequiredtohavewateratthesetemperatures:

•Between46°C-48°Cforwashingoperations.•Notlessthan80°Cforsanitising(onlywheresanitizingtakesplaceatthesink).

Adequatespaceshouldbeprovidedadjacenttosinksforholding,draininganddrying.

4.5.3 Janitorial Sink

Ajanitorialsinkwithhoseconnectionsshouldbeprovidedfordisposalofwastewaterinaseparateroom(fromfloorwashingetc.)

4.5.4 Dishwashers and Glass Washers

Thedishwasherandglasswasherneedtobeabletowashandrinseinonecontinuousoperationanddryrinsedutensilsbytheendofthecycle.

Section 4 Fixtures, Fittings and Equipment Section 4 Fixtures, Fittings and Equipment

p25

Wash Temperature

Thisisthetemperatureinsidethedishwasherwhenitiswashing.Thewashtemperatureistypicallybetween55°Cand56°C.

Rinse Temperature

Thisisthetemperatureofthefinalrinse.Toprovidethermaldisinfectionthedishwashermustrinseat82°Corabove,for at least 12 seconds.

Rinse Temperature Interlock

Fittedtothehigherspecificationmachines,thisdeviceextendsthewashcycle(ifneeded),toensurethecorrectrinsetemperatureisreachedbeforethedishwashercancompletethewash,thengointotherinsecycle.Machineswithoutrinsetemperatureinterlockscanwashandrinsebeforetheyarefullyuptotemperatureandproduceunsanitarywash results.

Section 5 Waste Section 5. Waste

This section refers to the appropriate disposal systems for specific waste products, adequate storage, ideal location and recycling. Proper storage and disposal of waste in the kitchen is vital in achieving a sanitary and pest-free environment that will reduce contamination.

Glossary

Impervious:Amaterialthatis,orismadetobe,resistanttowetsubstancespenetratingitssurfaceinanyway.

5.1 Disposal Systems

Disposal systems are the actions performed to remove waste in a commercial kitchen from the premises. The kitchen’s wastedisposalsystemshouldbedevelopedtopreventtheoccurrenceofinjuryresultingfrommanualhandlingtasks(e.g.liftingofwastecontainers).

Appropriate measures need to be taken to dispose of the following:

•Foodfordisposal.•Grease.•Garbage.•Recyclables.

Foodfordisposalisfoodthatis:

•Previouslyserved.•Unsafeorsuspectedofbeingunsafe.•Unsuitableorsuspectedofbeingunsuitable.•Toberecalledorreturned.•Outofdate.

5.1.1 Food / General Waste Disposal System

Food disposal system procedures ensure that food for disposal is not used in any food preparation. Allfoodfordisposalmustbeclearlyidentified.

Food for disposal must be isolated until it is:

•Returned.•Destroyed.•Disposed.•Alteredinawaythatdeemsitunsuitableforhumanconsumption.

Thedisposalsystemforfoodbeginswithidentifyingandthenaccumulatingthewaste.

There should be waste facilities located:

•Atthefoodpreparationarea.•Nearthewashingareafortheservedfoodthathasnotbeeneaten.

Wastefacilitiesareusuallybinswithlidslinedwithgreenbio-degradablebags.Garbagechutesmayalsoused.

Bins must be easily accessed:

•Accessibletoallareasinthekitchen.•Allbinsinthekitchenmusthavealid.

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Section 5. Waste

Waste Disposal

Holding Tank

Waste disposal separate line into tank

5.1.2 Recyclable Disposal System

Whendisposingofrecyclablematerialssuchasbottlesandcans,itiscommonpracticetofillbinsorcrateswithinthekitchenbeforemovingthecratesorbinsoutsideorintoaseparateroomforcollection.Ifaroomisusedforwastecollection,itshouldbeawayfromfoodstorageandpreparationareastoavoidcontamination.

5.1.3 Grease Disposal System

Qualified/trainedpersonsshouldemptygreasetrapsandarrestorsonaregularbasis.

5.1.4 Garbage Chutes

Wheregarbagechutesareusedforwastedisposal,theyshouldbemadeofstainlesssteel.Ifanypartofthechuteisinaccessible,itshouldincludeabuilt-inwashingfacility.

5.2 Storage

5.2.1 Waste Storage Containers

Everycommercialkitchenrequiresbothinternalandexternalstoragecontainerstoholdwasteandrecyclablematerialthatthekitchenproduces,untilitisdealtwithaccordingly.Toreducethepossibilitythatwastecollectionwillleadtofoodcontaminationand/orattractpests.

Waste containers should be:

•Sizedtohandletheexpectedvolumeofwaste.•Madeofanimperviousmaterial(e.g.stainlesssteel,plasticwillholdbacteria).•Clearlyidentified.•Appropriateforthecontents.•Adequatetofullyencloseitscontents.•Abletobecleanedwitheaseandwithadequateresults.•Designedandmaintainedsoastobesafeandnottoriskhealthandsafety.

Waste disposal/Macerator, when used in the kitchen shouldonlybepipedintoaholdingtankandundernocircumstancesshoulditgointothedrainage.Theholdingtankshouldbelocatedinaseparateroomfromthekitchen.Thiswillenabletheemptyingof the waste food and rule out any cross contamination within the kitchen area.

Wasteshouldthenberelocatedtoadedicatedwastedisposalarea,which is usually outside the back dooror in a separateroom. When transporting the waste it should never pass through the kitchen or restaurant area. It is common practice to take the binsorgreenbio-degradablebagsoutside toan industrialbinwheretheyareemptied.Iftheentirebinweretakenoutsideitshouldpreferablybeonwheelsforeasytransport.

Industrial binsmust be enclosed, sealed tightly with a lid,andopenedonlywhenfilling.Exposedwasteleftoutsidewillattract animals and pests. To avoid unpleasant smells from the decomposition of waste, a garbage contractor shouldcollect it at adequate intervals.

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Section 5 Waste Section 6 Flooring

5.2.2 Storage areas

Wastestoragecontainersrequirededicatedstorageareas.Theycanbekeptinanareaoutsidethekitchenorinaroomthatisdesignatedforthatpurpose.Ifaninternalroomisuseditshould:

1.Belocatedawayfromfoodlocationstoavoidpossiblecontamination.2. Have adequate ventilation.3.Preventtheentryandharbouringofpests.4.Ensurewaterthathasbeenusedincleaningtheareaexitsonlythroughadrainintogreasetrapanddoes not escape into other areas.

5.3 Location

Storageareasforwasteshouldbelocatedawayfromfoodstorageandpreparationareastoavoidcontamination.Waste material should never pass through the kitchen or restaurant area.

5.4 Flooring

TheFloorofwastecollectionareashouldbe:

1. Of solid construction.2. Made of impervious material.3.Havebundsforwasteoil.4. Graded into drainage point with an underground grease trap.

5.5 Cleaning

Whetherinternalorexternal,thewastecollectionareasandwastecontainerswillneedtobewasheddownregularly.Itisrecommendedtheyarewasheddowndaily.Forthisreasonthereshouldbeatapandhoseconnectioninthevicinity.Itisrecommendedthatthebinsarealsowasheddailyandgradedintoadrainagepointwithandundergroundgreasetrap.

The design of wash down areas must include special provisions to prevent contaminants and cleaning chemicals entering thestormwaterorsewagesystem.Agreasetrapcouldbefitted.

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Section 6 Flooring

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Thissectionprovidesinformationonflooringwithinacommercialkitchenarea,includingdrainageandselectionofmaterials.

Glossary

Coving: Thecurvingofafloormaterialattheintersectionofthefloorandwallsurfaces,soastomake a smooth and continuous curved skirting.Epoxy resins: Aresinbasedfloormaterialthatissealedforcommercialkitchenuseandisimperviousto moistureanddoesnotpromotetheharboringofdirtormould.Flooring substrate: Basesurfacetowhichflooringmaterialisapplied.Impervious: Amaterialthatisorismadetoberesistanttowetsubstancespenetratingitssurfaceinanyway.Welded joints: Joinsinplastic-basedfloormaterialsheat-treatedtocreateajointhatwillnotharbour moisture,dirtormouldwhencleaned.Thetermalsoappliestometalfloorsurfaces.

6.1 Floor Finishes and Serviceability

Floorsinfoodpremisesmustbeabletobecleanedeffectivelyandthoroughly,mustnotabsorbgrease,foodsubstancesorwater,harbourpests,andshouldbelaidsoasnottocausepoolingofwater.

Followingisalistofsuitablecommercialkitchenflooringsurfaces:

•Stainlesssteelwithanon-slipprofileandweldedjoints.•Ceramictileswithepoxygrouting.•Quarrytileswithimpervioussealer.•Polyvinylsheetortileswithheatweldedjoints.•Steeltrowelcasehardenedconcretewithepoxysealant.

TheuseofPVCsheetsortilesshouldbeavoidedadjacenttohotfatappliancessuchasdeepfryers.

Itisimperativethatallcommercialkitchenfloorsandstaffamenitiesfloorshaveanon-slipsurface.ThesesurfacesshouldmeettherequirementsofBSEN13036-4:2011.

Inallcases,installationshouldbeundertakenbyappropriatelyqualifiedtradespersonstoensureproperadherencetothesubstrate,andadequatesealingofjointstomaintainanimpervioussurface.

Flooringshouldbecleanedandmaintainedonadailybasis inaccordancewithmanufacturer’s instructions inordertomaintain slip-resistance.

6.2 Floor Drainage

Thesubstrateofcommercialkitchenfloorsshouldpreferablybeconcrete,andgradedtofloordrainageoutletstopreventpooling of water.

Specialattentionshouldbegiventotheinstallationoffloorfinishesatthejunctiondrainageoutletstopreventthebuild-upofdirtandgreaseandmaintaintheintegrityofthewaterproofing.

6.3 Floor and Wall Intersections

Thejunctionoffloorandwallsurfacescanbecomeasourceofcontaminationthroughthebuild-upofgreaseanddirt.Itisrecommendedthatthejunctionbecovedtoassistwithcleaning.

Section 7 Walls & Ceilings

Theinternalwallsandceilingsofacommercialkitchenmustbeappropriatelydesignedandconstructedtoachieverequired hygiene levels.

Glossary

Coving: Thecurvingofafloormaterialattheintersectionofthefloorandwallsurfaces,so as to make a smooth continuous curved skirting.Epoxy grout: Aresinandgenerallycementbasedmaterialthatadheresandsealstilesfor commercialkitchenuseandisapproximately99%impervioustomoisture.Fire resistance level: Thetimeittakesforastructuralelementtocatchonfire.Impervious: Amaterialthatisorismadetoberesistanttowetsubstancespenetratingitssurface in any way.Sealed: Amaterialthathasbeencoatedinaparticularwaysoasnottoletmoisture penetrate its surface.Suspended acoustic tile ceiling: Aceilingthatissuspendedfromtherooforfloorabove,andcomprisesindividual ceiling tiles in a grid.Welded joints: Wherejoinsinplasticbasedfloormaterialsareheattreatedtocreateajointhat willnotharbourmoisture,dirtormouldwhencleanedorafterhavingsomethingspilt on them.

7.1 Ceilings

Theminimumheightforaceilinginacommercialkitchenshouldnotbelessthan2400mm.Thisincludesducting,allpreparationandstorageareas.Allductingshouldbeenclosedabovetheceilingtopreventdustandinsectscollectingand falling in food.

Thefinishedceilingsurfacemustnothaveanyperforationorexposedjoints,cracksorcrevices.Thisistopreventthecontaminationoffoodandenableeffectivecleaningofthesurface.Thisalsoensuresthattheceilingispestproof.

Suspended acoustic tile ceilings are not permitted in food preparation areas or where food is displayed or served. Theyaredifficulttocleantotherequiredhygienestandardsandmayharbordust,greaseandinsectsatthetopofthe drop ceiling.

Thewall-to-ceilingjunctionmustbetightlyjoinedandsealed.Thejunctionmustbeconstructedsothatnodust,greaseorfoodparticlescancollectinthejoint.

Whereasealantisusedintheceilingjointitmustbemadeofamaterialthatisimperviousandwashable.

7.2 Walls

Thefinishesonthewallsmustbeimpervioustogrease,foodparticlesandwater.Thefinishmustbesmoothandeven.Thesurfaceshouldhavenobuckles,ledgesorexposedfixings.Thefinishedsurfaceofthewallsmustbeeasytoclean.

Recommendedfinishesinclude:

•Ceramictileswithanti-bacterialgrout.•Stainlesssteeloraluminiumsheetwithweldedjointsandsealedfixings.•Laminatedplasticsheeting.•PVCsheeting,thisisweldedattheseams.

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Section 8 Ventilation

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Thissectionreferstothemanagementofairqualityinsideacommercialkitchen,theamountofairflow,itssupplyandtheexhaustofairbornecookingwaste.

Aneffectivecommercialkitchenventilationsystemrequires‘airbalance’,inwhichtheexhaustingoffumes,smoke,greaseandsteamisbalancedbytheintroductionoffresh,cleanair.Inbusykitchenswherepeoplearegenerallywork-ing close together there is a need for some form of controlled ventilation and air conditioning. The kitchen exhaust system is an essential part of the cooking process. The presence of fumes, smoke, grease, steam and vapours pollutes theatmosphere,mayinterferewithfoodflavoursandaromas,andcausedistresstostaff.

Glossary

Airborne: Transportedbytheair.Duct: Tubeorchannelforconveyingair.Make-up air: Theairneededtoreplacethewasteairthathasbeenextractedfromtheroom.Vapour: Theair-likesubstanceintowhichcertainliquidorsolidsubstancescanbeconvertedbyheating.Vent: Anopeningallowingairtopassoutoforintoaconfinedspace.

8.1 Natural Ventilation

Anadequatesupplyofcleanairmustbeprovidedandmaintainedwithinacommercialkitchenusinggas.Thesimplestformofventilationisnatural,involvingtheuseofwindows,ventsandskylights.Theseshouldallowsufficientairflowtomaintainahealthyworkingenvironment.Allventsshouldbescreenedtopreventfliesandberodentproof.

Ifnoreplacementairbynaturalormechanicalmeans,theventilationwillsucktheairfromtherestaurantdrawinginthewarmair/coolairfromtherestaurantincreasingtherunningcost.Replacementairprovidestheairflowrequiredbyexhaustsystems.Ifreplacementairdoesn’tcomeintotheroom,thentheexhausthoodmaynotcaptureandcontainairbornecookingwasteduetothereducedairflow.Thiscouldallowcookingodoursandwasteairtoescapeintothedining area. If there is no replacement air in kitchen, when using gas appliances, lack of replacement air can cause the gas burnerstogooutbecauseoflackofoxygen.

Considerablecareshouldbetakenwheredoorwaysandwindowsareusedfornaturalventilationthatfumes,dirtand rodents from surrounding premises are not drawn into the kitchen.

8.2 Exhaust Systems

Exhaustsystemsaremadeofanumberofinterdependentunits.Exhausthoods,exhaustfans,make-upairunits,andpackagedrooftopHVAC(HeatingVentilationAirConditioning)unitsallneedtooperatewithindefinedparametersto complement one another and to maintain peak performance.

The exhaust canopy must cover all cooking appliances with an overhang of 150mm to capture the cooking fumes.

Aneffectiveexhaustsystemshouldgetridof:

•Heat.•Particulatematter.•Greaseladensteam.•Cookingvapours.

Exhausthoodsshouldbeplacedabovecookingequipmentandhavetheabilitytocaptureandcontaintheairbornewastematterproducedbycookingequipment.

Exhaustfansmustbecapableofremovingthecollectedairbornewastesatarateequivalenttotheirgeneration,andmake-upairunitsneedtobecapableofreplacinganequivalentvolumeoftheextractedwastefumes.Thereplacedaircanbeheated,cooledordehumidifiedasnecessarybytheHVACunitworkinginunisonwiththeotherunits.

Section 8 Ventilation

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The important issue here is interlocking. This means that where there is a ventilation hood over the cooking area, thereisagassupplycut-outmechanismbetweenthecookingequipmentandtheventilationhood.Iftheextractionfanshouldfail,thegassupplytothekitchenequipmentwillbeautomaticallyturnedoff.

Interlocking regulations now prevent the operator from turning on the gas equipment without turning on the ventilation. If theventilationfailsthereisabypasssystemwhichgivesalimitedtimeinordertogetanengineertofixtheproblem.Therules say that any new kitchen using a fan-assisted extraction system must have this interlocking gas cut-out system. Also, ifmorethanhalfoftheappliancesarereplacedinexistingkitchens,thenaninterlockinggascut-outsystemmustbefitted.

Thelocationofmake-upairunitsinthecommercialkitchenshouldbepositionedasfarawayaspossiblefromthesourceofthepollutantstomaximizecrossventilation.Allexhaustgasesshouldbedischargedtotheatmospherethroughductsandcarefulconsiderationshouldbegiventotheseparationofexhaustdischargefromair-intakesandfromneighbouringproperties.

8.3 Airflow Plan and Design

Itisimportantthatallcommercialkitchenshaveaneffectiveairflowplan.Theplanshouldtakeintoaccountallequipmentthatproduceswasteair(cookingequipmentanddishwasher)andthenbalancethiswithcleanmake-upair.Theextractionofwasteairandintakeofcleanairshouldformastableairflowpatterninsidethekitchen.Thekitchenstaffshouldallbeawareofthisplan,understandhowitworksandbepreparedtoactifanyproblemsarise.

8.4 Mechanical Air Replacement

MechanicalAirReplacement(MAR)intakemustbelocatedasfarfromtheexhaustoutletfromthekitchenaspossibleandconsiderationofthesurroundingbuildingse.g.paint/carbodyshops,duetotheodoursthesecreate.

MARshouldhaveaveryfinefiltertopreventthesmallestflying insectsenteringthekitchen.Thesecandestroyprepared food.

Contractors must record all maintenance activity in maintenance schedules.

8.5 Environmental Considerations

Toreduceenergyconsumptionthroughbackairconditioning,foodpremisesshouldconsiderthefollowinginthespecificationanddesignofventilationsystems:

•Utilisenaturalventilationwherepossibleandwhereairconditioningisrequireduseefficientcentralplantwithlocalcontrolsoverpackageunitsifpossible.Wherethisisnotpossible,selectenergyefficientpackageunits.•Undertakeanenergyauditpriortoanewfitoutanddevelopanenergyreductionstrategyaspartofthefitoutservicesdesignbrief.

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This section provides recommendations for the design of lighting in a commercial kitchen.

Glossary

Diffuser: Acoveroveralightfittingwhichpromotesanevendistributionoflightthroughoutthearea.Glare: Lightthatistoobrightorintense.Illuminance level: The amount of light falling on a surface.Luminance level: Theamountoflightthatisreflectedfromasurface,suchaswalls,floorsandceiling.Splash back: Anareaofimperviousmaterialsuchasmetal,tilesetcwhichisfixedtoawallbehinda workbenchorsink.

9.1 General Requirements

Adequateandproperlydesignedlightingisessential inacommercialkitchenforstafftoefficientlydotheirtasksincludingcooking,cleaning,foodpreparationandpresentation.Theareashouldbeasfreefromglareandunwantedreflectionsasispracticable.

Thedesignofalightingsystemshouldtakeintoaccount:•Availablenaturallight.•Requiredluminancelevels(lux)forthetasksbeingperformed.•Reflectanceofsurfaces.•Emergencylightingrequirements.

A properly designed lighting system will help to reduce energy costs and improve the working environment for staff. In addition,electricalsupplysystemsandemergencylightingmustcomplywithBS5266:part1:1999.Itisrecommendedthatqualifiedelectricalengineers,designersand/ortradespersonsareengagedtoensurecompliance.

9.2 Natural and Artificial Lighting

Therelationshipbetweennaturalandartificiallightingisimportanttoconsiderwhenlightingacommercialkitchen.Whileartificiallightingwillnormallybethemainsourceoflight,itisdesirabletoincludenaturallightsources.Ideallywindowsinthekitchenshouldnotbelessthan10percentofthetotalfloorarea,andshouldlookoutontotheskyor open space.Windows and skylights can provide views and allow light into a space, improving the staff working environment, howevertheycanalsobeproblematicasasourceofglare.Carefulconsiderationshouldbegiventothepositioningofwindowsandtheinteractionbetweennaturalandartificiallightlevels.The recommended luminance level for a commercial kitchen’s general working area is 160 lux. For food preparation, cookingandwashingareastheluminanceshouldbe240lux.Dessertpresentationsandcakedecoratingrequire400- 800 lux.

9.3 Reflectance

Interferingreflectionsandglarecancausereducedvisibilityandbecomeasourceofdistractionandannoyance.

Lightwillreflectoffwalls,ceilings,floorsandworksurfaces.Therefore,thecolour,materialandtypeoffinishofthesesurfacesshouldbecarefullyconsidered.Thereflectancefromthesesurfacescontributestotheoverallluminancelevel of the area.

Takingtheseconsiderationsintoaccountwillresultingoodvisibilityconditionsforthekitchen.Ceilingsoccupyasubstantialamountofthefieldofview.Forlargeareaswherethereisindirectlightpenetratingthespace,itisadvisabletorendertheceilingwhiteornearwhite.Regardlessofthesizeoftheroomstheceilingshouldhaveareflectancelevelascloseto70percentaspossible.Wallreflectanceisimportanteventhoughitscontributiontothedistributionoflightissmall.Thecoloursandfinishesshouldbeselectedtakingintoaccountcontrastsbetweensurfaces.Forexample,thereshouldbeadifferencebetweenthebenchandwall.Finishesshouldnotprovideglareyetprovideenoughreflectivelightforstafftosafelyandeffectivelycarry out their tasks.

Section 9 Lighting

Section 9 Lighting

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9.4 Light Fitting Considerations

Lightfittingsneedtobeinstalledinsuchawaythatwillnotcontributetofoodcontamination.Theyshouldalsobedesignedandinstalledinawaythatfacilitateseaseofcleaning.Fittingsshouldbegenerallyrecessedorsurfacemountedinceilings,thefittingsshouldhaveasealedunittostopthedustfallingfromthelightse.g.Perspexcover.Suspendedfittingswillcollectdustandbecomeasourceofcontaminationtofood.

Properlydesigneddiffusersshouldbeinstalledtoassistwithevendistributionoflightandcontainfragmentsintheeventofaglobeshattering.Theluminancelevelshouldbemadeatleast100luxhigherthantherecommendedlevel,becauseofalightlossfactorthat occurs over time.

9.5 Emergency Lighting

•Emergencylightingensuresthatpatronsandstaffareabletobesafelyandeffectivelyevacuatedfromthepremises.•Emergencylightingturnsonautomaticallyfromitsownpowersupplywheneverthereisapowerfailure.•Theemergencylightsmustbepositionedatexits,atanypointwherethereisapotentialhazard(e.g.achangeinfloorlevel)andatregularintervalstomaintainminimumlightinglevels.•Thelocationofemergencylightsshouldnotcauseexcessiveglareandinterferewithapersontryingtoleave the premises.

Emergencylightingsystemsmustbemaintainedonaregularbasisandmaintenancechecksrecordedinalogbook.

9.6 Environmental Considerations

Toreduceenergyconsumptionthroughlightingincommercialkitchens,considerationshouldbegiventothefollow-ingintheselectionoflightingelements:

•Fornewlightingtokitchen,storageandallback-of-houseareasselectT5fluorescentlampswithelectronicballasts.•Forfrontofhouseareasconsiderreplacingincandescentlampswithlowenergylamps(e.g.compactfluorescentwhereverpossible)•UseT5fluorescentlampsinsignageandmenuboards.•Inexistingfluorescentfittings,re-lampwithtri-phosphorlampsandundertakere-lampingandcleaningprogramsonaregularbasis•Installmovementsensorstostoreroomsetc.toensurelightsareturnedoffwhennotinuse.•Commercialkitchenmanagers/ownersshouldcontacttheirlocalenergyproviderandconsiderswitchingto greenpower.•Undertakeanenergyauditpriortofitoutanddevelopanenergyreductionstrategyaspartofthefitoutservicesdesignbrief.

Themostimportantconsiderationistodecideonaprojectbyprojectbasiswhatwillprovidetheoptimumsolutionconsidering all environmental issues in a holistic manner.

•Directenergyuse.•Selectionofmaterialsandequipmentthatminimizeembodiedenergy.•Allowforachievingafullusefullifethrougheaseofmaintenance.•Provideanoptimumqualityoflightfortheusersofthespace.•Provideforre-useandrecyclingatendoflifeoftheentireinstallation.•Considerquantityandmaterialsoflampsandlightsourcesconsumedinthelifeoftheinstallation.

Therelativeweightingsofthesecriteriashouldbeconsideredandmatchedtoeachproject.Theresultwillbeacompromisebasedonexperienceandjudgementtakingintoaccountrelevantlegislation.

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Section 10 Storage

Thissectiondescribesthestorageareasthatneedtobeprovidedforfooditemsinacontrolledenvironmentandtoseparateotheritemsthatmaybethesourceofcontaminationoffood,includingchemicals,clothingandpersonalbelongings.

Glossary

Process:Theactivityofpreparingfoodforsaleincludingchopping,cooking,drying,fermenting,heating,pasteurising,thawingandwashing,oracombinationoftheseactivities.Ready-to-eatfood:Foodconsumedinthesamestateasthatinwhichitissoldanddoesnotincludenutsintheshellandwhole,rawfruitsandvegetablesthatareintendedforhulling,peelingorwashingbytheconsumer.

10.1 Storage Requirements

Theneedforseparatestorageroomswilldependonthescaleofthekitchen,however,considerationshouldbegiventospecificstorageneedsforthefollowing:

•Drygoods.•Chilledandfrozenfoods.•Freshfruitandvegetables.•Returned/recalledfoods.•Packagingmaterial.•Cookingutensilsandequipment.•Cleaningequipmentandchemicals.•Clothingandpersonalbelongingsofstaff.•Garbageandrecyclablematerials.•Storagefacilitiesmustallowthesaferetrievalofstoreditems.•Wasteoilstorage(bunding).•Stafflockers.

Waste/Refugestorage Chilledgoodsstorage Ambient(drygoods)storageTotal0.04–0.06m2/seat 0.21–0.26m2/seat 0.21–0.26m2/seat 0.46–0.58m2/seat

10.2 Hazardous substances

Hazardoussubstances,includingcleaningagentsandpestcontrolchemicalsmustbestoredinanarea(cupboardorseparateroom)dedicatedtothatuse,andlocatedawayfromfoodstorageandpreparationareas.Hazardoussubstances(includingdecantedhazardoussubstances)mustbeclearlyandappropriatelylabeled.

Section 11 Pest Control

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Thissectionreferstopreventingpestsinacommercialkitchen.Themajorreasonsforpestsenteringakitchenaretosearchforfood,waterandshelter.Itshouldbenotedthatitwillusuallycostmoretoremovepeststhanitwilltopreventthementeringinthefirstplace.

Glossary

Air curtains: Machinetypicallymountedaboveanopening, (althoughverticalmounting isalsopossible)thatcreatesanair draftacrossanopening,whichpreventsflyinginsectsfromentering.Bait: Product designed to lure and kill pests.Fly door: Doorthatallowsairtoflowthroughbutnotpests.Fly strips: Rowofover-lappingplasticstripsthathanginadoorwaypreventingentrybyflyingpests.Harbour: Refuge, shelter, secure.Penetration and service areas: Areaswherepipesandwiresetcgothroughwalls,floors,roofsetc.Pests: Nuisance animals, insects etc.Traps: Deviceusedtosealpassagessothatsubstancescan’tescape.

11.1 Prevention

Liveanimals(exceptshellfishandthelikeusedinfoodpreparation)arenotpermittedinanycommercialkitchen.Foodpremisesshouldbedesignedtominimizethepossibilityofanyanimalorpestenteringorharbouringwithin.

Thefollowingmeasuresshouldbeadoptedtominimizetheriskofpestsenteringthefoodpremises.

Externally

1.Prunebacktreesthatover-hangtheroof.2. Maintain a minimum 1200mm wide free draining paved surface around the premises.3.Avoidstoringwastebinsagainstexternalwalls.4. Install rodent proof strips at all entrance doors.5. Install self-closing devices on entrance door.6. Cover external vents with wire mesh.7.Sealservicepenetrations(electricalandplumbingservices)inexternalwalls.8.Installprofiledsealingstripsatthejunctionofroofsandexternalwalls.9.Ensurewindowsaretightlyfittingandinstallflyscreenswheretheycanbeopened.

Internally

1.Ensurefloorsinwetareasareproperlygradedtopreventpondingofwater.2.Repaircracksandgapsinwallswhichmayharbourpests.

Waste management

Implementacontrolledwastemanagementsystem(refertosection11ofthisdocument).

Storage areas

Inregardstopestcontrolinstorageareas,thefollowingactionsshouldoccur:

1. Inspect stock daily.2.Rotatestockonaregularbasis.3. Install appropriate exhaust systems.4. Position store room racks 600mm from the walls.

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Section 11 Pest Control

11.2 Insect Control

Despitebesteffortsandgoodpractice,insectsmaystillenterthekitchen.

Flying insects canbeeliminated through theuseof insect controldevices, e.g. electronic insectkillers. It isrecommended that such devices are located at entrances to eliminate the insects on entry. Ideally the insect controldevicewillcontaintheinsectsalthoughifthedevicekillsthebugcausingthemtodrop,considerationmustbegivenastowheretheinsectswilllandsothattheydonotcontaminatefoodorfoodpreparationareas(UVbulbsmustbechangedasmanufacturerinstruct).

Ventilationintakemusthaveafilterfittedtostopfliesandotherairborneinsectsbeingintroducedtothekitchenarea e.g. prep sweet areas.

Crawlinginsectscanbecontrolledthroughtheuseofbaits,e.g.cockroachbaits.Somefoodpremiseschoosetokeeppermanentbaitsonthefloorwherefoodislikelytobedropped,aroundovensforexample.Othersusebaitsonlywhenthereisaconcern.Baitsshouldnotbeplacedanywherewheretheycouldcontaminatefood.

11.3 Monitoring

Everycommercialkitchenshouldhaveadocumented,servicedandverifiedpestcontrolprogram.Aregisteredserviceshouldbecontactedforanappraisal.ComponentsandpestcontrolregimesshouldbemonitoredbyalicensedpestcontrollerwhoisQAaccredited,foodsafetyassured,hastheappropriateinsuranceandisapproved.

Section 12 Signage

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This section aims to increase awareness and provides detailed information concerning the importance and the different types of signage that can be found in a commercial kitchen or in a food business premises.

Glossary

Directional:Alineorapathinwhichapersonmoves.Signage: Somethingthatindicatesafactorrequirementthatisnotimmediatelyobvious.

12.1 Emergency Signage

12.1.1 Exit Signs

Exit signs are required to direct people to exit doors in the case of an emergency.Theymustbeinstalledsotheyareclearlyvisibleatalltimes.Wherethelocationoftheexitisnotreadilyapparent,the exit sign must also include directional arrows to indicate the path of travel.The design of exit signs must comply with the requirements of Health and Safety at work Act 1974.

12.1.2 Fire Emergency Signage

Itisnecessaryinacommercialkitchentoprovidesignagethattellstheoccupantswhattodointheeventofafire.Theseinclude:

•Signsdetailingtheemergencyevacuationplanforthebusiness.Staffshouldbemadeawareofwhereemergency evacuation procedures are written down.•Instructionalsignsadjacenttofireextinguishers,fireblanketsandfirehosereelsdetailingtheircorrectuse.

12.1.3 First Aid Signage

•Signsshouldbeinstalledtoclearlymarkthelocationoffirstaidkits.Itisimportantthatallstaffbemadeawareofthelocationanduseoffirstaidkits.•ItisalsorecommendedthataposterbedisplayedtoexplainthecorrectproceduresofCPR(CoronaryPulmonaryRespiration).

12.2 Hygiene Signage

12.2.1 Personal Hygiene Signage

Personal hygiene of staff is important to prevent contamination of food.

Postersorsignsshouldbedisplayedinkitchenstomakestaffawareof:•Thecorrectproceduresforwashinghands,andwhenthismustbedone•Whatdointheeventofaminorillness(forexample,acold)•Thebusiness’spoliciesregardinggrooming,clothes,wearingofjewellery,tyingofhairetc.

12.2.2 Kitchen Hygiene Signage

Postersshouldbedisplayedthatdetailtheproceduresnecessarytokeepthekitchencleanandhygienic.Theseposters should include guidelines for different areas of food preparation, processing and storage. They should also provide a detailed description of the cleaning requirements of each area.

12.2.3 Check Lists

To keep track of hygiene and cleanliness issues, a checklist of procedures is recommended. The checklist should provide abriefdescriptionofwhatisrequired,withotherrelevantinformationsuchasthecleaningprocedure,andthecleaningproductusedtoachievethebestresult.

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Section 13 Staff Amenities

12.2.4 Cleaning Chemicals Signage

As different cleaning products generally perform different duties it is important to display a sign in the commercial kitchenexplainingtheuseandpotentialhazardsofeachproduct.Cleaningchemicalsmusthaveaseparatelockableareaforstorage.Itisadvisabletocolourcodechemicalsastowhichareatheycanbeusedin.

12.3 Equipment Signage

It is recommended that signsbe installedadjacent toequipment thatexplains their correctuse includingsafety requirements, and procedures for cleaning.

This section describes the amenities that should be provided for the staff of a food business.

13.1 Storage of Personal Items

Staffshouldbeprovidedwithadequateandsecurestorageforclothingandpersonalbelongings.Ifnotlocatedindedicatedstaffchangerooms,lockersshouldbelocatedawayfromfoodpreparationandstorageareastopreventpossiblecontaminationoffood.

13.2 Change Rooms

Staff shouldbeprovidedwithdedicatedchangerooms,particularlywhentheyarerequired towearuniforms.Genderspecificchangeroomsarenotnecessaryforsmallbusinesses;howevertheyshouldbeprovidedforlargerfoodbusinesses,andmaybeincorporatedintotoiletareas.Changeroomsshouldnotopendirectlyontokitchenareas.

13.3 Toilets

It is essential that staff have access to toilets.

Forasmallbusinesslocatedinashoppingcentre,useofthecentre’spublictoiletsmaybeadequate.Forlargerbusinesses,staffmaysharethetoiletfacilitiesprovidedforpatrons;however,itisrecommendedthatdedicatedstafftoiletsbeprovided.Wherenomorethan10staffareemployed,aunisextoiletmaybeprovided.Aunisextoiletmustincludeonepan,onebasinandmeansofdisposingsanitaryproducts.

Wheremorethan10staffareemployed,separatemaleandfemaletoiletsshouldbeprovided.Thenumberofsanitaryfixtures(toiletpans,urinalsandbasins)thatmustbeprovideddependsonthenumberofstaffandissetout in the Building Act 1984.

Toiletsmust not open directly into kitchens or food storage areas and should be accessed via airlockswithself-closing doors.ToiletsmustbeadequatelyventilatedinaccordancewiththeBuildingAct1984.

13.4 Storage of Office Materials

Officematerialsandpaperworkshouldbestoredinaroomdesignatedforofficeuse,orlocatedincupboardsthatarededicatedtostoreofficematerials,andbelocatedawayfromthefoodpreparation,cookingareas.

13.5 Wash Hand Basins

Staffmusthaveaccesstowashhandbasins/Quadwashfacilitiesaftervisitstothetoilets/smokingareas(contaminationfromlighters/cigarettepackets).

Washhandbasinsmustbelocatedwherestaffmovefromoneareatoanothere.g.fromprepareatocookingarea.Taps/handles/pushplates/lightswitchesshouldbesanitizedonaregularbasisduringtheday(recordfrequencyondailysheets)

Section 14 Fire Safety

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Information on fire and evacuation processes is listed below, and only covers what is required for commercial kitchens. The requirements for the rest of the building must be incorporated throughout the kitchen. This is supplemental information.

Basicfireprecautionsare:

•Allareasshouldbekeptcleanfromdust,dirtandoiltolimitfiredamage.•Allcookingandhigh-riskappliancesshouldbewatchedwheninuse.

14.1 Emergency Procedures

Allkitchensmusthaveawrittenemergencyevacuationplaninplace.Thisplanshoulddetailthefollowingactions:

•Whenthealarmisactivatedtherestaurant’sfirewardenshouldreceivethefirstwarning.(orifpartofalargerbuildingtheirfirewarden)•Untilthenatureofthealarm,whetherfalseorreal,isknown,employeesandcustomersshouldcontinueasperusual.•Oncethefirewardenhasassessedtheproblem,heorshemustcalltheappropriateservicesanddecideuponevacuation.•Staffandcustomersarethentobeevacuatedinanorderlyfashionasplannedandpracticedonpreviousoccasions.•Onceevacuated,staffaretoassembleinapredefinedplaceandawaitfurtherinstructions.•Thefirewardenistostayandwaitforemergencyservicesandassistthemifpossible.•Adebriefingshouldoccuraftereachevacuation(trainingorreal)toidentifyproblemswiththeprocessaswellas to point out the positive aspects.•AllareasofrestaurantsMUSThaveatleastonetrialevery12monthperiod.

14.1.1 Emergency Manuals

All manuals for emergency devices, solutions to dangerous situations and other emergency instructions etc. should bekeptinthesameplace.Theymustbeclearlylabeled,wellorganizedandeasytounderstand.Ifinstructionsareattachedtothedevice,itisadvisabletokeepaseparatecopywiththeothermanuals.

14.2 Emergency Devices

•Emergencydevicesshouldbedispersedaroundthekitchen,notallinthesamearea.•Emergencyequipmentshouldbeservicedatleastonceayear.

14.2.1 Fire Extinguishers

•Themostcommoncauseofseriousfiresincommercialkitchensistheover-heatingofdeepfryeroil.

•Itisrecommendedthatallextinguishers/blanketsusedinthekitchenaresuitableforhotoilfires.

•Howmanyextinguishers?

•Thenumberofextinguishersisdependentonthesizeofthekitchen.

Location

•Theyshouldbeinamainthoroughfare,preferablyalongtheexitroute.•Theyneedtobeeasytoaccessinahurry.•Theyshouldbe100mmhighoffthefloor;thetopoftheextinguishershouldbe1200mmfromthefloor.•Forelectricalfirestheextinguishermustbecloserthan40mfromtheappliances.•Forcookingoilsandfatstheextinguishersmustbeplacedbetween2and20mfromtherisk.Ina commercial kitchen 20m is too far away, it is safer to keep them within 10m.

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Section 14 Fire Extinguisher Table

Type ofExtinguisher

Type ofFire

Water

Foam ABF FoamOnly

ABC Dry Powder

SpecialDry Powder

Co2

WetChemical

FOR USE ON:

Wood, Paper and Textiles

AFOR USE ON:

FlammableLiquids

BFOR USE ON:

FlammableGases

CFOR USE ON:

FlammableMetals

DFOR USE ON:

ElectricalHazards

FOR USE ON:

Cooking Oilsand Fat

F

3 7 7 7 7 7

3 3 7 7 7

3 3 3 7 3 7

7 7 7 3 7 7

7 3 7 7 3 7

3 7 7 7 7 3

* A Powder Extinguisher will leave a residue that can damage sensitive electrical equipment. If possible, use a CO2 Extinguisher.

Maintenance / Servicing

ServicingoffireextinguishersmustbeinaccordancewithBritishStandardsbyalicensedengineer.Itisrecommendedthatacompanythatschedulesregularvisitsformaintenanceisused(orcontracted)toensuretheequipmentiskepttostandard.

Service record

Apermanentrecordmustbekeptofallservicingthatwillsequentiallyrecordallmaintenancecarriedoutoneachfireextinguisher,including:

•Typeofextinguisher,e.g.BEpowder.•Dateofmanufacture.•Recordofthelastservice.After6yearsanewextinguisherisneeded.12yearsisacceptableonlywhentheextinguisherisnotsubjecttoenvironmentalextremes,suchassteamorhightemperatures.Thisextensionispermittedifagreeduponbyowner and servicer.•Anydefectsandtheactiontaken.•Arecordofmissingormisplacedextinguishers.•Anyotherrelatedcomments.

Thisrecordcanbealogbook,acomputer-basedrecordsystemoranotherpermanentrecordthatiseasytointerpretforreportsandfor referencing to an individual extinguisher.


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Theowner/agentandtheservicepersonshallsigneachrecord.Recordtagsarenotacceptableasmaintenancerecordsystem,thoughrecordtagsmustalsobekeptonanextinguisher.

MarkingEachextinguishermustshowapermanentlyfixed,uniqueidentificationmarkwhichcanbereferencedbacktothemaintenancerecords.Themarkcanconsistof:•Writtennumbers,lettersoracombinationofboth.•Barcode.•Magneticorelectronicstripe.g.smartchip.

OtherForextinguishersinstalledwherethetemperaturescanreachabove50°corbelow5°ctheextinguishermustbeenclosedin a thermally protected case.

14.2.2 Fire Blankets

Fireblanketsareonlytobeusedtoextinguishsmallcookingandclothingfires.

Primary information

Eachfireblanketmustbemarkedwith:•Thewords‘fireblanket’inlettersgreaterthan25mminheight,inacontrastingcolourtothebackground•Instructionsonhowtoextinguishacookingfireinpictureform:

1. Gentlycoverthefirecompletelywiththefireblanket. 2. Turn off the source of heat. 3. Leavethefireblanketinplaceuntilcool. 4. Callthefirebrigade.

•Illustrationsonhowtoextinguishaclothingfire(onfireBlanketslargerthan1.2x1.8m): 1. Stop victim from moving. 2. Quicklywrapthefireblanketaroundthevictim. 3. Dropvictimtothegrounduntilthefireisout. 4. Rollthevictimonthefloor. 5. Seek medical assistance.

•Amessageincontrastingcolourthatsays:‘Warning:thisfireblanketisnotofadequatesizeforadultclothingfires’orwordstoasimilareffectonblanketsthataresmallerthan1.2x1.8m.•Instructionsregardingdisposaloftheblanketafteruse.

Secondary informationBlanketsarekeptinmountedbags,markedwiththefollowing:•Nameandaddressorregisteredtrademarkofthesupplierandthemanufacturer’strademarkifdifferent.•Manufacturer’sbatchidentificationcodeordateofmanufacture.•Sizeoftheblanketinmetresbymetres.•Thewords‘notforelectricalfire’ifthematerialhaslessthan1MWelectricalresistance.•Foldinginstructionspreferablyinpictureform.

Howmanyfireblankets?Incommercialkitchenswithfiveorlessfirehazardsinthesameareaonefireblanketwillsuffice.Inalargerkitchenmorearenecessary.Theymustbecloseenoughtothehazardstobeaccessedquickly.

LocationFireblanketsmustbeinanobviousandaccessibleplace.Thisareamustnotendangertheuserwhentheyreachforitinanemergency,e.g.notthefarsideofdeepfryer.Ifmorethanonefireblanketiskeptinthekitchenthentheyshouldnotallbekeptnexttoeachother.Thisallowsmorethanonepersontohelpfightafire.

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Themountingoftheblanketmustbestrongenoughtowithstandsomeonepullingthefireblanketfromitscontainer.Theremustalsobeenoughroomtoquicklyopentheblanketwithoutobstruction.

Size•Fireblanketsmustbeeitherrectangularorsquarewithnosidebiggerthan1.8mandnosmallerthan0.9m.•Afireblanketcannotweighmorethan10kg.•Itwillhavehandleswithwhichtoholdtheblanket.•ItMUSTbefoldedcorrectlysothatwhenneeded,itcanbeopenedinlessthanfourseconds.•ItmustcomplywithBS9999:2008.

Maintenance / ServicingInspectionoffireblankets/emergencylightingmusthappenevery12months.Thiscanbedoneinconjunctionwithfireextinguisherservicing.

Thischeckshallinclude:

1.Accessibility •Cantheblanketclearlybeseen? •Canitbeeasilyaccessed? •Isitwhereitshouldbe? •Hasitbeeninstalledcorrectly? 2. The Fire Blanket Sign •Isitvisible? •DoesitconformtotheBSEN1869:1997?

3. Fire Blanket Bag •Isitsecureinplace?Thisincludesthesupport. •Isitcleanandundamaged? •Aretheinstructionsclearandlegible? •Isthemaintenancetagattached?

4. Blanket •Isthereanydamage? •Isitfoldedcorrectly? •Arethehandlessecureandundamaged?

5.Informationforfirewardens •Oilstorage. •Cardboard/Paperstorage. •Gascylinderstorage.

Servicing recordAllmaintenanceandamendmentsmustberecordedonthemaintenancetab.

14.2.3 Other Equipment

Fire hose

Firehosesarenotgenerallyusedinakitchenprimarilybecausewaterisvolatileagainstfats,oilsandelectricalfires,butifuseditmustcomplywithBSEN15889:2011.

Gas suppression systemsA gas suppression system works well. These generally have a pipe system that goes up the wall with nozzles in the rangehood.Theseareexpensivebutagreat investmentastheyaredirectlyoverthehazardandareusuallyheatactivated.

Aswithmostfiresafetydevices,ifusedinaconfinedspace,thenthereisariskofasphyxiationaswellaslimitingvisibility.Onceusedandthefireisout,leavetheroomuntildangerousvapoursdisappear.Ifmorethanonefireblanketiskeptinthekitchenthentheyshouldnotallbekeptnexttoeachother.Thisallowsmorethanonepersontohelpfightafire.


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Sprinkler systems

Sprinklersystemsaswithfirehosesarenotgenerallyusedunlessthekitchenislarge,mainlyduetotheirhighexpense.If a sprinkler system is used, a misting type is generally recommended. They are however, very important for the eating area.Restaurantsandcafésmustcomplywithallfiresafetystandardsforthisoccupancytype.Ifasprinklersystemisrequired in the restaurant.

Fire detection systems

These are more of a precaution than a solution. Smoke detectors do not work very well in kitchens. Steam and other vapoursdisrupttheefficiencyofsmokedetectors.Alsosmall,easilycontainedfiresareacommonoccurrenceincommercial kitchens that may unnecessarily trigger a smoke alarm. It is recommended to use heat detectors instead. Smoke/heatdetectorsarenottobeplacedmorethan20mapartandnotmorethan10mfromanywall.Gasshutoffvalve.Thisshutsoffthegastoappliancesinthekitchen.Thisshouldbesituatedattheexitsofthekitcheneasilyseenandaccessible.

14.3 Emergency Signage

ForEmergencySignageinformationturntothesectiontitledSignage,thenfindtheheadingEmergencySignageonpage 38.

14.4 Staff Training for Emergencies.

14.4.1 Fire Extinguisher Training.

Atleastonestaffmemberwhoistrainedintheproperuseofafireextinguishershallbepresentwhilethekitchenisoperating.Themorewhoaretrained,thesaferthekitchenwillbe.

14.4.2 Evacuation Training

Eachstaffmembershouldbetrainedintheskillandknowledgetohelpthemcopeinemergencysituations.

Theyshouldbetrainedinthefollowing:

•Whateachofthealarmsmeans:Aredifferentcoloursfordifferentemergencies?Whatistheevacuationalarm?•Preparingforemergencies:Ifafireblanketisnotwhereitissupposedtobe,whatshouldbedone?•Howandtowhomshouldemergenciesbereported.•Reactingsafelytoemergencies.•Evacuatingfromdangerousorsoontobedangerousareas.•Emergenciesthatmayoccur.•Whatareunsafesituations.•Howtofixorreportunsafesituations.•Responsibilitiesofthewardens.•Wheretoassembleafterevacuationandwhathappensoncethere.

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This section refers to the requirements for access and egress from commercial kitchens.

Glossary

Egress: Awayout.Exit: Adoorwayleadingtoaroadoropenspace.FireCompartment: Apartofabuildingseparatedfromtheremainderbybarrierstofiresuchaswallsandfloors withanappropriateresistancetothespreadoffire.

15.1 Provision for Escape

Thedesignofanycommercialkitchenmustallow:

•Safeandconvenientmovementabouttheworkplace•Safeegressfromtheworkplaceinanemergency•Safeaccesstoanypartoftheworkplace.

Provisionmustbemadeforsaferoutesoutofthebuildingincaseoffireorotheremergencies.Itisimportanttoensurethattheseexitsremainunobstructedandthattheescaperouteiseasytopassthrough.

Wherenopointonthefloorismorethan20mfromanexit,onlyoneexitisrequired,otherwiseatleasttwoexitsarerequired.Wheretwoormoreexitsarerequired,thedistancebetweenalternativeexitsmustcomplywithlocalbuildingregulations.

Anexitmustleadtoadesignatedsafearea/musterpoint.

Theunobstructedheightofthepathoftraveltoanexitmustnotbelessthan2000mm.

Theunobstructedwidthofthepathoftraveltoanexit(excepttheactualdoorway)mustnotbelessthan1000mm.

Suitablebarriersshouldbeputinplacetopreventvehiclesfromblockingtheexit,oraccesstoit.

15.2 Access for People with Disabilities

Asfarasisreasonable,acommercialkitchenshouldbedesignedtoprovidesafe,equitableanddignifiedaccesstopeoplewithdisabilities.

Section 15 Access & Egress

Section 14 First Aid

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Thissectiondescribestherequirementsforfirstaidkitsinfoodbusinessesandrequirementsforstafftraininginfirstaid.Restaurants,hotelsandclubsarein‘GroupA’,thelowestriskgroupinregardstofirstaid.AllthefollowinginformationadherestotheHealthandSafety(First-Aid)Regulations1981,otherstateswillhavesimilarlawsthatshouldbecompliedwith.Itisusefultoknowwheretheappropriateexternal medical or occupational health services are in case of an emergency, where the closest appropriate hospital or clinic is, how long itwilltaketogetthereandhowanemployeewouldbetransported.

16.1 First Aid Kits

16.1.1 How Many?

OneBasicFirstAidKitmustbekeptonthepremisesforevery50staffwhoareworkingatonetime.For50to100staffanOccupationalFirstAidkitisrequired.Ifmorethan100thentwokitsarerequired.Theratioofkitsperpeoplemustbemaintainedwhenthenumberofstaffincreases.Inadditiontothekititishighlyrecommendedthataburnmoduleandeyemodulealsobeincluded.Forover400staffafirstaidroomisnecessary.

16.1.2 Location

Thekit/smustbeinanobviousandeasilyaccessiblelocationatalltimes.Thekitwouldbemoreusefulifitwereofthewallmountabletypeasiscommonpractice,soitisalwaysinthesameplace.Howeveramobilekitmeetslegalrequirements.Allstaffmusthaveafirstaidkitwithin100moftheirregularworkposition.Atleastonekitmustbeoneachalternatelevelofamulti-levelkitchen.

16.2 Number of First Aid personnel required.

1. From your risk assessment, what degree of hazard is associated with your work activities?

2. How many employess do you have? 3.Whatfirstaidpersonneldoyouneed?

Low Hazard

e.g.offices,shops,libraries

Less than 25 At least one appointed person

25-50 Atleastonefirst-aidertrainedinEFAW

More than 50

Atleastonefirst-aidertrainedin FAW for every 100 employed (orpartthereof)

Higher Hazarde.g.lightengineeringandassembly work, food processing warehousing, extensive work with dangerous machinery or sharp instruments, construction, chemical manufacture.

Less than 5 At least one appointed person

5-50

Atleastonefirst-aidertrainedinEFAW or FAW depending on the type of injuriesthatmightoccur.

More than 50 Atleastonefirst-aidertrainedinFAW forevery50employed(orpartthereof)

TheAlulineGroupcannotacceptresponsibilityforanyerrorsoromissionscontainedinthisinformation.

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