Market Forge Industries MT-40 Specifications

MT 24/40 gallon SERIES
MODULAR BASE DIRECT STEAM TILTING KETTLES
INSTALLATION - OPERATION - MAINTENANCE
models
‰‰MT-25
‰‰MT-40
44 Lakeside Avenue, Burlington, Vermont 05401 USA
Telephone: (802) 658-6600 Fax: (802) 864-0183
www.mfii.com
PN 14-0323 Rev B (4/15)
© 2015 - Market Forge Industries Inc.
Your Service Agency’s Address:
Model
Serial number
Kettle installed by
Installation checked by
TABLE OF CONTENTS
IMPORTANT
WARNING: Improper installation, adjustment, alternation,
service or maintenance can
cause property damage, injury or death. Read the installation, operation and maintenance instructions thoroughly
before installing or servicing
this equipment.
FOR YOUR SAFETY
DO NOT UNDER ANY CIRCUMSTANCE CONNECT THE
EXHAUST DRAIN LINE DIRECTLY TO A SEWER LINE.
Do not store or use gasoline or
other flammable vapors or liquids in the vicinity of this or any
other appliance.
The information contained in this
manual is important for the proper installation, use, and maintenance of this kettle. Adherence
to these procedures and instructions will result in satisfactory
baking results and long, trouble free service. Please read
this manual carefully and retain
it for future reference.
ERRORS: Descriptive, typographic or pictorial errors are
subject to correction. Specifications are subject to change
without notice.
INSTALLATION
Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooking Facts for Steam Jacketed Kettles.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooking Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE
Cleaning the Kettle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction
Service:
Market Forge tilting direct steam jacketed kettles of two
capacities, each mounted in a modular stainless steel
cabinet.
Required service, both repair, replacement, and adjustment is explained in Adjustments section of this manual.
Other service help can be found in the Trouble Shooting
and Maintenance sections of this manual. Should repairs
be required, a network of Authorized Service Agents is
available to assist with prompt service. A current list of
Authorized Service Agencies may be obtained by contacting Market Forge direct of going on our website www.mfii.
com.
Double wall construction around the lower half of the
kettle forms a surrounding chamber into which steam is
introduced as a source of heat for cooking.
Steam input plumbing is equipped with a manual control
valve. Condensate is removed through a steam trap connecting with the kettle drain plumbing assembly. A swivel
spout, hot-cold combination faucet provides a source of
water for addition to the kettle for cooking and cleaning.
The model and serial number must be referenced when
corresponding with Market Forge. These numbers can
be found on the data plate located on the upright frame
behind the cabinet base door. If you require further assistance in obtaining these numbers, please contact us
directly.
Large capacity kettles are fitted with heavy duty tilting
mechanisms operated by removable hand crank. Each
model is equipped with a pan support which maintains
continuous alignment of serving pans under the pouring
spout at all levels of kettle elevation. Counterbalanced
hinged lids cover the kettles in the lowered position. All
are plumbed for direct connection to a remote steam
source.
Applicable model designation includes:
•
MT-25 (25-gallon) – 36” wide (914mm) cabinet base
•
MT-40 (40-gallon) – 36” wide (914mm) cabinet base
Installation
2
Service Connections
SERVICE CONNECTIONS
DIMENSIONS ARE IN INCHES [MM]
Hot Water - 3/8” (10mm) 3/8” (10mm) NPT for hot
water to faucet. Hot water line will have a maximum of
50 PSI (3.5kg/ cw2) and a minimum of 25 PSI (1.8 kg/
cw2) water pressure (Water may be filtered).
CW
Cold Water - 3/8” (10mm) NPT for cold water to faucet.
Cold water line will have a maximum of 50 PSI (3.5kg/
cw2) and a minimum of 25 PSI (1.8 kg/cw2) water
pressure.
D
Drain - Pipe full 2” NPT (51mm) to flush floor drain. Do
not make solid connection to drain.
CR*
Optional Condensate Return - 1/2” NPT (13mm)
connection for condensate return from kettle when
specified.
EC*
Electrical Controls - 115 volts AC, 60 Hz, 40 watts,
1/2” (13mm) conduit connection or equivalent. Use wire
suitable for at least 90°C. Draws less than 1 Amp with
power lift.
D
CR
HW
15 [381]
2.88
[73]
S
11.5
[292]
2.5 [64]
5 [127]
15 [381]
EC
1.75 [45]
6.38 [162]
66.5
[1689]
Maximum
Height
Recess area for kettle draw-off (dotted line) must be kept free of
all piping and connections.
7 [197]
6 [152]
PVC and CPVC pipe are not acceptable materials for drains.
CR
Separate height for 25 and 40 gallon kettles.
43 [1092]
28 [711]
22 [559]
Pressure-reducing valve is required if incoming pressure exceeds
30 PSI (2.1 kg/cm2).
21 [533]
NOTES:
38 [965] MT-40
S
* Optional
33 [838] MT-25
CW
4 [102]
DRAW OFF AREA
33 [838]
HW
36 [914]
4 [102]
13.88 [352]
Steam Supply - 3/4” (19mm) NPT, 15 P.S.I (1.0 kg/
cm2) minimum; 30 P.S.I (2.1 kg/cm2) maximum.
13 [330]
S
D
EC HW CW
MT-40
POUR PATH
6 [152]
Figure
10 1
[254]
3
8 [203] MT-40
Installation
Operating Instructions
Pan Support Mounting Tilting Kettles
All kettles must be supplied with steam from a boiler
which is remotely located. Consult steam boiler information or instruction plate and complete all start-up instructions. Proceed with kettle operating procedure as follows:
For convenience during cooking, the pan support need
not be installed until needed for removing food from the
kettles. To ensure correct operation and to prevent spills
the support must be securely installed as shown in “Figure 3” and as explained below:
1. Check pressure gauge of steam supply source to insure steam input is at 15 PSI (1.0 kg/cm2). For direct connected steam, turn on external steam supply
valve.
1. Hold the pan support in front of the upright as shown
at A.
2. Check that Draw-Off Valve is tightly closed.
2. Place the stud of the left-hand support upright into the
hole in the left side of the pan support. Then push the
right side of the support in until it engages the spring
loaded pin of the right-hand support upright, shown
at B.
3. Lift kettle lid and place either a Solid or Perforated
Drain Disc over the drain inside kettle. Use solid disc
to retain liquids; perforated to strain liquids from food.
4. Load kettle with foods to be cooked.
3. Rotate the pan support upward (C) and engage the
slotted ends of the support links in the studs at the
base of each support upright as in D.
5. Add water for cooking by swinging spout over kettle
and using Combination Faucet.
6. Turn Steam Control Valve to full counter-clockwise
position to heat kettle content to an initial rapid boil.
The removal procedure is the reverse of installation with
the exception that in step 2 support upright springs must
be pushed out to release the support from studs.
NOTE: The volume of steam going into the kettle
jacket can be controlled at any time by adjusting the kettle steam control valve in either
direction. Turn clockwise to reduce heat and
counter-clockwise to increase.
7. Close Steam Control Valve (full clockwise position)
when cooking is complete.
STEAM CONTROL
VALVE
caution
HOT AND COLD
FILL FAUCET
Food must be removed from the kettle immediately.
8. Remove food from tilting kettles. With a full pan in the
pan support, and the crank installed in the front of
the cabinet, turn the crank clockwise to tilt the kettle
for pouring. (Tilting mechanism is infinitely adjustable and non-coasting in kettle elevation and lowering). Liquid foods may also be removed by use of the
Draw-Off Valve.
CRANK HANDLE
(MANUAL TILT)
Figure 2
operation
4
Cooking Facts for Steam Jacketed Kettles
A Steam Jacketed Kettle is a stainless steel kettle jacketed or encapsulated by a second outer kettle, creating
a space between the two kettles. Cooking is achieved by
allowing steam to flow within this space. The jacket or
outer kettle usually covers 2/3 of the inner kettle, although
some kettles are fully jacketed
The steam flowing in the space between the kettles condenses on the cold inner kettle wall and releases heat
through the wall to the food in the kettle. The condensate
drains to the bottom of the kettle and is released through
a steam trap without any loss or variation in steam pressure. The amount of steam allowed to flow Into the Jacket
controls the heat of the kettle. In use, the Steam Jacketed
Kettle provides consistent heat distribution and is energy
efficient using steam only to maintain pressure, unlike top
of the range cooking in which energy (gas or electricity) is
used during the entire cooking process.
Steam Jacketed Kettles can sauté, simmer, or boil a
wide variety of products, such as soups, gravies, sauces,
pasta, stews, mixed casserole type dishes, vegetables,
shellfish, cereals, hot beverages, and puddings. A Steam
Jacketed Kettle will not burn foods. However, foods that
caramelize at relatively low temperatures, such as eggs
and milk based products, will coat and cook onto the
sides of the kettle. Care should be taken to use the smallest flow of steam, to lessen the possibility of scorching
these products. To achieve this, allow products to come
up to desired temperature, stirring frequently, then turn off
steam flow and gradually turn on a small flow of steam just enough to allow food to cook.
•
Estimate actual cooking capacity of Steam Jacketed
Kettles at 3,4 of its volume, to allow stirring without
spillage.
•
Plan an adequate drain arrangement. This is very
important for ease of use and to minimize wet floors.
A grated gutter type drain located in front of the
kettles is preferred as it eliminates the hazards of
tripping over a curb or stumbling into a recessed
drain area.
•
Locate a source of water (swivel faucet or flexible
hose type) near the kettle to facilitate filling and
cleaning.
•
Cover products whenever possible to save energy.
Covered water boils 25 to 30% faster.
•
Use the tangent draw off valve to drain off products
from the kettle such as sauces and puddings, or
cooking liquids that are being discarded (as in the
case of the water used to cook pasta)
•
Remove the tangent draw off valve after each use
for cleaning, using a brush to clean draw off as
bacteria will readily multiply in this area if it is not
thoroughly cleaned.
•
Use the optional solid kettle disk when product is not
going to be dispensed through the draw off valve,
and the perforated disk when draining off liquids
through the draw off valve and retaining the solid
product in the kettle.
Steam Jacketed Kettles eliminate much range top cooking and greatly reduce the number of pots and pans required. Because they are made of stainless steel, they
are durable, non-porous and easy to clean.
Figure 3
5
operation
Cooking Chart
This chart merely shows single load capacities as it is felt that in most cases the kettle would be used only once per meal.
ITEM
COOKED PORTION SIZE
KETTLE SIZE
25 gallon (95 liters)
40 gallon (150 liters)
Yield: 20 gal. (75 l.)
Yield: 35 gal. (132 l.)
Portions = 425
Portions = 745
Amt. Raw: 20# (9 kg.)
Amt. Raw: 36 #
Portion = 270
Eggs: 90 dz. 18 gal. (120 l.)
(16.3 kg) Portion = 480
Eggs: 160 dz., 32 gal. (166.5 l.)
Portions = 540
Portions = 960
Yield: 17 gal. (64.3 l.)
Yield: 30 gal. (113.5l.)
Portions = 545
Yield: 20 gal. (75 l.)
Portions = 960
Yield: 35 gal. (132 l.)
Portions = 640
Portions = 1120
Yield: 17 gal. (65 l.)
Yield: 30 gal. (113 l.)
Portions = 360
Yield: 20 gal. (75 l.)
Portions = 640
Yield: 32 gal. (120 l.)
Portions = 500
Yield: 17 gal. (65 l.)
Portions = 800
Yield: 30 gal. (113 l.)
Portions = 270
Yield: 17 gal. (64 l.)
Portions = 480
Yield: 30 gal. (113 l.)
Portions = 425
Yield: 17 gal. (64 l.)
Portions = 750
Yield: 30 gal. (113 l.)
Portions = 545
Portions = 960
Yield: 20 gal. (75 l.)
Yield: 35 gal. (132 l.)
Portions = 1200
Portions = 2000
Amt. Raw: 20 gal. (9kg.)
Amt. Raw: 35 # (15.8kg.)
Portions = 220
Amt. Raw: 20 gal. (9 kg.)
Portions = 385
Amt. Raw: 35 # (15.8 kg.)
Portions = 320
Yield: 20 gal. (9 kg.)
Portions = 560
Amt. Raw: 35 # (15.8kg.)
Portions = 320
Portions = 385
BEVERAGES
Cocoa or Coffee
6 oz or 3/4 cup (180 ml.)
BREAKFAST FOODS
Cereal
Scrambled Eggs
6 oz or 3/4 cup (180 ml.)
4 oz or 2 eggs each (115 g.)
DESSERTS
Cornstarch Pudding
4 oz. or 1/2 cup (120 ml.)
Gelatin
4 oz. or 1/2 cup (120 g.)
MAIN ENTREES *
Macaroni, Beef and
Tomato
6 oz. or 3/4 cup (170 g.)
Baked Beans
5 oz. or 2/3 cup (140 g.)
Beef Stew
8 oz. or 1 cup (225 g.)
Macaroni and Cheese
5 oz. or 2/3 cup (140 g.)
Turkey A La King
4 oz. or 1/2 cup (115 g.)
MISCELLANEOUS
Gravy/Sauce
2 oz. or 3/4 cup (60 ml.)
MACARONI AND RICE
Noodles
4 oz. or 3/4 cup (115 g.)
Rice
3 oz. or 1/2 cup (85 g.)
Spaghetti or Macaroni
4 oz. or 3/4 cup (115 g.)
* All main entree figures are given in terms of raw ingredients.
operation
6
Cooking Chart
ITEM
COOKED PORTION SIZE
KETTLE SIZE
25 gallon (95 liters)
40 gallon (150 liters)
Yield: 20 gal. (75 l.)
Yield: 35 gal. (132 l.)
Portions = 400
Yield: 20 gal. (75 l.)
Portions = 700
Yield: 35 gal. (132 l.)
Portions = 325
Portions = 560
Amt.Raw: 80#. (36.3kg.)
Amt. Raw:120 # (54.4 kg.)
Portions = 335
No. Of Packages: 50
Portions = 500
No. Of Packages: 80
Portions = 550
No. Of Packages: 25
Portions = 880
No. Of Packages: 40
Portions = 275
Portions = 440
SOUPS
Basic Cream Soup
Broth Type Soup
6 oz. or 3/4 cup (180 ml.)
8 oz. or 1 cup (240 ml.)
VEGETABLES
Fresh
4 oz. or 1/2 cup (115 g.)
Frozen Loose Pack
4 oz. or 1/2 cup (115 g.)
Frozen Solid Pack
4 oz. or 1/2 cup (115 g.)
7
operation
Cleaning the Kettle
The most important preventive maintenance operation on the steam jacketed kettle is the daily cleaning
procedure after each use.
8. Wash inside of draw-off valve with a nylon brush.
All kettle cleaning procedures should be faithfully completed by the end of each day’s operation. In addition,
cabinet doors, top, fixtues, kettle lid, etc., should be
washed and rinsed to remove all food spills.
1. Fill kettle with water and mild detergent immediately
after removing food from kettle.
2. Scrub kettle interior with a nylon brush.
NOTE: NEVER SCRAPE KETTLE INTERIOR WITH
METAL TOOLS, STEEL SCOURING PADS
OR ABRASIVE CLEANERS. Scratches will
result, which will ruin the kettles general appearance and make it harder to clean and
maintain in a sanitary condition.
Figure 5
9. Rinse kettle valve interior and reassemble valve.
NOTE: Leave draw-off valve open when kettle is not
in use.
3. Loosen food which is stuck to kettle by allowing it to
soak. Also, a small amount of steam may help.
10. Remove swivel drain and its strainer. Wash, rinse and
replace.
4. Position swing drain under draw-off valve. Open
draw-off valve to drain soapy water.
Tilting Mechanism Lubrication
Lubrication of the tilting mechanism is the only required
preventive maintenance other than daily cleaning.
5. Wipe down exterior, rinse and dry. Avoid getting water
into electrical controls.
1. Inspect the screw of the tilting mechanism annually
for adequate lubrication.
warning
2. If screw appears “dry”, apply good grade bearing
grease directly on the threads so that the threads appear to be barely damp.
DO NOT HOSE DOWN UNIT AS IT MAY CONTAIN ELECTRICAL COMPONENTS.
6. Remove strainer from inside kettle. Wash and rinse
thoroughly.
7. Disassemble draw-off valve by first turning valve
handle counterclockwise. Then, turn hex nut counterclockwise until valve handle and stem are free.
Large Nut
Figure 4
maintenance
8