2013 AMC Leadership Conference

2013 AMC Leadership Conference
2013 AMC
Leadership Conference
Popping Tips from
Gold Medal Products Co.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Popping Tips from:
Gold Medal Products Co.
10700 Medallion Drive | Cincinnati, OH 45241
gmpopcorn.com | 800-543-0862
January, 2013
1. Always use the correct measure of popcorn, oil and salt for the best results. If you do not know the size of your
popper call Tim Lawson at Gold Medal (866-417-1551) and he can help you determine the correct size. You can
call about any manufacture’s popper. Popcorn Oil to Corn ratio (30% oil) is critical and should be checked often,
especially if you notice poor popcorn quality. There are instructions in the manual on how to adjust the oil charge
or call Tim Lawson at 866-417-1551.
2. With the correct popcorn, oil and salt measurements, the popping cycle should be between 2 minutes/ 50 seconds
and 4 minutes. To calculate the popping cycle pop at least four batches before you measure the popping cycle to
make sure the kettle is fully heated for maximum performance. Start “the clock” when you have loaded all the
ingredients for the fifth batch and stop “the clock” once you have finished dumping the fifth batch kettle. This
cycle time should be within 2 minutes/50 seconds and 4 minutes.
3. If the batch takes longer than 4 minutes, the kettle temperature is too low and the corn will not pop fully and may
be slightly burned. You should stop using the kettle and immediately call a certified technician to repair the kettle.
4. If the batch is less than 2 minutes/50 seconds, the kettle is too hot and the corn will not pop as it should. Corn that
pops too fast will look like mushroom (balled/rounded) corn rather than butterfly popcorn. You should stop using
the kettle and immediately call a certified technician to repair the kettle.
5. When popping always leave the popper doors open for the moisture to escape, so the corn does not become soggy.
6. When finished popping make sure the doors are closed to keep the heat inside the cabinet and the popcorn warm.
7. Popcorn that comes directly out of the kettle does require 3 to 5 minutes before enough moisture is out of the corn
to be saleable, otherwise it may be soggy. “Drying Times” may vary due to the conditions (humidity, temperature
etc.) in a particular theatre.
8. Always check to make sure the blower/warmer (located under the corn pan) is operating correctly. At least once a
month, the blower/warmer should be taken apart to clean (with a shop vacuum) any small pieces that may have
gotten into the enclosure. If the debris is left to build up it can cause the blower/warmer to not operate to its
maximum performance. The correct temperature of the corn should be between 120 to 130 degrees F throughout
the product stored in the cabinet. Corn that is stored at less than 120 to 130 degrees F will gather moisture
quicker.
9. The temperature of the air coming out of the blower/warmer should be at least 130 degrees F.
10. All theatre model poppers have filter systems that need to be cleaned at least once a week. There have been
several different systems over the years so read your manual to see how many and what type of filters are required
for your unit. If they are missing they should be replaced immediately after cleaning the area where the filter will
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com be installed. Some filters can be washed with soap and water (check your manual). It is very important to keep
whatever system you have in good working order.
11. NOTE: if you have a Gold Medal PopClean® Popper the only filter that can be washed is the aluminum first stage
baffle filter. The other two filters are not visible and should not be washed. When those two filters are saturated
you will be signaled by the popper that they need to be replaced.
12. When sifting any un-popped kernels from the finished corn inside the cabinet be sure to use “metal to metal”
contact between the scoop and the bottom pan. Gently bring the corn up and over the holes in the bottom corn pan
so the un-popped kernels go into the tray below the holes. Never dig into the pile of popcorn with the scoop as
you will break the ears off the corn and dramatically reduce the size of the popcorn which will increase costs and
decrease quality.
13. Once you have gently filled the popcorn container with product do not shake, crush or in any way try to force
more corn into the package. You will only break the corn and wind up serving a poor product. Your customers
want a large and tender product—not pieces of broken popcorn.
14. Always make sure that the lights both behind the display sign and in the cabinet are working for the best
appearance of the popcorn and equipment.
15. Never use a cleaner with ammonia on any plastic or plexiglass parts (especially doors) as it will cause them to
crack.
16. Never put the kettle in or near water. Electricity and water do not mix. There is no need to remove the kettle for
cleaning. Use the “clean in place” latch to hold the kettle in the proper position. See your manual for more details
on how to use the “clean in place” latch.
17. If you pull your popper out for cleaning always make sure that the main power cord plug is properly installed in
the wall receptacle. Sometimes by moving the popper the connection between the plug and receptacle can become
loose. Also be careful not to roll the popper over the power cord.
18. When storing popcorn kernels, do so in as close to a sealed container as possible. Remember that popcorn will
continually lose moisture, so once a bag is opened be sure to use it up as fast as possible so it does not dry out.
Make sure that popcorn kernels are not stored in a remote stand or they will dry out. Dried out corn will not pop
to their fullest potential and will result in burned, small popcorn.
19. Inside the kettle you will see the stir rods on the bottom of the kettle. These rods should be 1/8” off the bottom
cook surface for proper agitation of the corn. If they are too high the corn will not stir correctly and may tend to
burn.
20. Make sure that all warning stickers are in good condition. If they are not then order replacements.
21. If you do not have a manual send an email to: [email protected] and request a replacement. In the email be
sure to include the Model Number of the Popper and Date of Manufacture both can be found on the data plate.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Preventive Maintenance/Cleaning Tips:
“Standard” Filter Cleaning
1.
Loosen the 2 screws on the filter cover plate on the ceiling inside the popper. Remove the cover, the bag and mesh filters.
Clean the bag filter and the mesh filters in warm soapy water. Let dry overnight and reinstall.
CAUTION: Keeping the filters clean is important to let the exhaust system do its’ job.
2.
Check the condition of the clear oil lines and tighten or replace as required.
ITEM NO
1
2
3
PART NO
41250
41169
82015
DESCRIPTION____________________________________________________
Metal mesh filter
Oil Mist Bag Filter
Filter Pack (Includes all three filters)
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com PopClean® Filter Instructions:
Clean the Baffle Filter
1. Lift the baffle filter towards the top of the popper. Swing the bottom end clear of the mounting brackets and
remove the filter. Clean the filter in warm soapy water, allow to air dry, then replace. Do not attempt to clean
the bag, or HEPA filters.
Box and HEPA Filters:
1. Note: The bag, and HEPA filters are not to be cleaned. When then “check filter” light comes on, be prepared
to change either the bag filter – or the HEPA filter. (The HEPA filter should last twice as long as the bag
filter.) When the “change filter” light comes on, the machine will be inoperable until the bag and/or HEPA
filter is replaced.
Filters for Downdraft Models
Item No.
Part No.
Description
1
62709
Baffle filter
2
62710
Box Filter
3
62711
HEPA Filter
4
63300
Filter Plug
Baffle Filter
Filter Plug
.
Box Filter
HEPA Filter
Filter Plug Installed
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Filters for Updraft Models
Item No.
Part No.
Description
1
63222
Baffle filter
2
63304
Box Filter
3
62711
HEPA Filter
Baffle Filter
Box Filter
.
HEPA Filter
Filter Access – Downdraft Models
Baffle Filter
Slide filter towards top end. Swing bottom end of filter clear of retainer clips and remove filter.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Bag and HEPA Filter
Loosen three door latches by rotating counterclockwise and open access door. Slide bag filter towards opening to remove. Lift HEPA
filter up until it clears the door opening and remove.
Note: All filters must be in place before the Kettle Heat switch will be active.
Filter Access – Updraft Models
Baffle Filter
Slide filter towards top end. Swing bottom end of filter clear of retainer clips and remove filter.
Bag and HEPA Filter
Loosen three door latches by rotating counterclockwise and open access door. Slide bag filter towards opening to remove. Lift HEPA
filter up until it clears the door opening and remove.
Note: All filters must be in place before the Kettle Heat switch will be active.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Oil Setting Instructions:
E-Z SET TIMER OPERATION
This machine is equipped with a programmable timer for setting the amount of oil needed for popping popcorn. Holding the red Oil
Dispense push button down while turning on the Oil System Master switch; while continuing to hold the red oil dispense button for
five seconds puts the unit in the program mode. The oil system master switch light will start to blink off and on indicating that the
timer is in the program mode. Hold a cup under the oil line and then use the manual mode of operation to prime the oil line. After
priming the oil line, use a measuring cup and the automatic mode of operation to set the correct oil amount.
AUTOMATIC OPERATION
When in the program mode press and release the oil Dispense switch to start the oil flowing. When the correct amount of oil has been
dispensed into the measuring cup (P.N. 62807) push the oil Dispense switch to stop the oil flow. The oil amount can be “topped off”
by pushing the oil Dispense switch on/off as many times as needed to finalize the oil amount. Turning the Oil System Master switch
off and then back on puts the unit in the regular mode. The unit will now dispense the “programmed” amount of oil when the oil
Dispense switch is pushed. The oil light will light only when the oil pump is on.
MANUAL OPERATION
When in the program mode, immediately turn off the Oil System Master switch; turning the Oil System Master back on puts the timer
in the manual mode of operation. The unit will now dispense oil only while the oil Dispense switch is pushed.
NOTES:
Model 2257D has the capability of “remembering” two different settings for poppers with the “Salt/Sweet” option or “Flexi-Pop
option.
For Salt/Sweet models, just put the switch in the “salt” position, and set the oil amount as described above. Then put the switch in the
“sweet” position and repeat the setting procedure. The pump will remember both settings.
For Flexi-Pop models, just put the “Load” switch in one position, 32oz. for example, and then set the oil amount. Then put the load
switch in the other position, 18oz. for example. And repeat the setting procedure.
Model 2457S is the heated line option for the 2257 pump.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Cleaning the Warmer Compartment
1. This element will be covered underneath corn pan inside the warming assembly. For proper operation, you MUST remove
cover and clean underneath the element every 3-4 months. Be sure machine is off and power is disconnected before
cleaning. Use a vacuum to clean out any popcorn crumbs, then re-install cover.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Converting Flood Lamps to LED:
LED KIT – P/N 55413L
LED Installation
This service bulletin describes how to replace the two incandescent bulbs in a 2011E or 2911E type popcorn machine with LED lights.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Unplug the machine
Remove the dome.
Remove the light bulbs from the conical light holders
Cut both sets of black and white wires 2” back from the conical shaped light holders. See figure 1. Leave the black and white
wires in the machine that went to the light holder opposite the kettle side of the machine. Remove from the machine the black
and white wires (above the kettle) going to the terminal block. See figure 2
Line the corn pan with newspaper or paper towels to catch the metal shavings from drilling the rivets. Use a 3/16” drill to
remove the 3 rivets holding each conical shaped light holder mounted to the motor plate. Removing the kettle from the
machine will make drilling the rivets easier. See figure 3.
Using the holes left by the rivets mount the two LED light holders in the motor plate. Mount the LED holder with the two
long wires in the hole above the kettle. On the side opposite the kettle, mount the power supply bracket to the top of the
motor plate across two of the LED holder mounting holes. See figure 4.
Wire the LED holders and power supply as shown in figure 5.
Plug in the machine and verify the lights work.
Unplug the machine and replace the dome.
If you have any questions, please feel free to call Technical Service at Gold Medal.
Figure 1:
Figure 2 :
Figure 3:
Figure 4:
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com Converting Flood Lamps to LED (Con’t):
Figure 5:
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com DAILY KETTLE CLEANING
1. As you pop corn, wipe the kettle with a clean cloth. It is easy to keep the outside clean when the
kettle is warm and the oil is not baked on.
CAUTION: The hot kettle will cause burns if you touch it with your hand.
2. Every night, mix a gallon of Heat’n Kleen solution (Gold Medal Part No. 2095) 2 tablespoons per
gallon of water. Add enough solution to fill the kettle ½” deep. Turn on the kettle heat. When the
water starts to boil, turn off the heat and let it work overnight.
3. The next morning, dump the solution in a bucket and wipe the inside of the kettle with a cloth.
4. A Clean-In-Place hook is located behind the operator side kettle support arm. With the lids and
crossbar assembly removed, just tilt the kettle to the dump position, and swing the hook into position
to hold the kettle in the dumped position. This feature will help you clean the kettle.
Clean‐N‐Place
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com 32oz Grand Pop-O-Gold
2848ED, 2860ED, 2872ED, 2872ED, 2861ED, 2873ED
Electrical Specifications:
120/208v or 120/230v 4 wire (2 hot, 1 neutral, 1 ground) 60 Hz.
5760 watts 30 amp plug & receptacle (NEMA L14-30P & L14-30R ),
Two (2) separate foot power cords are supplied with Twin Kettle models
All models are available for 230v 50Hz. Power Supply for export outside USA.
Agency Approvals:
UL, CUL, NSF
Oil Delivery System:
All Grand Pop-O-Golds are equipped with provisions for a Bag-In-Box System (2257). The Twin Kettle
versions are equipped with two systems, one for each kettle.
Lighting:
All models are available with either an illuminated red & white “popcorn” sign or a Neon sign with red
“popcorn” and yellow “puffs” on each end. All domes are reversible for front or back counter. Add a suffix,
N, to model number if neon is desired.
Model Numbers
Options:
2848ED Single Kettle Models
48” Cabinet length
2860ED Single Kettle Models
60” Cabinet length
2861ED Twin Kettle Models
60” Cabinet Length
2873ED Twin Kettle Models
72” Cabinet Length
N(neon “Popcorn” sign) All models have Deep Well popcorn bins.
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com PopClean® Downdraft
models 2848(32oz.), 2948(52oz.)
1ST STAGE GREASE BAFFLE
FILTER AND CONTROL PANEL
48”
Features:

Requires only 6 inch to flammable materials on open side.

Stainless Steel Construction.
Electrical Specifications:
ND
2848 (32oz) -
120/208v or 120/230v 4 wire (2 hot, 1 neutral, 1 ground) 60 Hz.
2 STAGE FILTER RD 6570 watts 50 amp plug & receptacle (NEMA 14-50P & 14-50R )
2948 (52oz) -
3 STAGE HEPA FILTER NOT
120/208v or 120/240v 4 wire (2 hot, 1 neutral, 1 ground) 60 Hz.
8270 watts 50 amp plug & receptacle ( NEMA 14-50P & 14-50R )
Filter / Ventilation Specification:

Tested and approved to ANSI/UL 710B (Integrated recirculating ventilation system / Ductless Hood) including the models with the optional Fire Suppression
System.
U.L. standard requires the grease laden effluent does not exceed 5mg/cu.meter. Actual test results for 52oz. popper was approximately 1 mg/cu.meter. (32oz is
proportionally less)

Filtering system consists of grease baffle, oversized pleated main filter, and final HEPA box filter. Caution lights alert operator to replace filters when required.
Oil Delivery System:
Bag-in-a-Box System model 2257 is included. The 2114 is the Accumeter bucket style system, available on request. For
poppers with Salt/Sweet or Flexi-pop options, oil system with 2 oil settings is supplied. (2257D, 2114D)
Lighting:
All models are available with either an illuminated red & white“popcorn” sign or a Neon sign with red “popcorn” and
yellow “puffs” on each end.
Options:
Export (230v-50Hz.), Neon “Popcorn” sign, Pass thru cabinet, Salt-Sweet
Flexi Pop ( 2848 32oz / 18oz., 2948 52oz. / 32oz ), Ansul R102 fire suppression (complete system built in popper, inc.
manual pull station, 3 gallon tank, switch for alarm system interface)
Agency Approvals:
ETL, CETL, ETLs
_______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com _______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com _______________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com 32 Oz. Pop-O-Gold Kettle Identification:
This section will assist with the identification of a 32 Oz. Pop-O-Gold kettle. There are many kettle variations; many can NOT be
interchanged with each other. It is extremely important to identify the correct kettle model number before ordering replacement parts
or a replacement kettle.
The first step is to locate the data plate on the bottom of kettle assembly. The kettle’s model number will be stamped into this plate.
Please note the following illustration:
If for some reason, the data plate is missing or damaged, the kettle can also be identified by referring to the following pictures of the
plug installed on the end of the kettle lead-in/power supply cord. NOTE: If the data plate is missing, stop using the kettle
immediately; remove the kettle from the machine and/or lock-out the popcorn machine per your internal Lock Out/Tag Out procedures
to prevent any accidental contact with the live electrical terminals located inside the junction box.
The kettle’s “dump” hand is best described when the technician is standing on the operator’s side of the machine, i.e. the operator’s
“RIGHT” hand/arm is used to dump the kettle; vice versa for a “LEFT” hand kettle. This same “RIGHT” and “LEFT” hand
nomenclature also applies to PASS THROUGH kettles.
1. Non-electronic machines made between 1993 and 1999:
Models 2011TM (Domestic) and 2011TX (Export) with no “E” in the
model number suffix.
Domestic Item Numbers:
Kettle Complete: 2027
2027DH (Pass Thru)
Export Item Numbers:
Kettle Complete: 2027EX
Lead-In Cord P/N:
Kettle Receptacle P/N:
Kettle Lead-In Cord P/N: 61082
Kettle Receptacle P/N:
41516
61082
41516
Picture of 61082 Cord:
Note Pin #5 is
Empty.
________________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com 2A. Electronic machines made between 1999 and 2004 w/ RIGHT Hand Dump:
Models 2011E (Domestic) and 2011XE (Export) with an “E” in the
model number suffix.
Picture of 48290 Cord:
Domestic Item Numbers:
Export Item Numbers:
Kettle Complete: 2027E
Kettle Complete: 2027EEX
2027EP (Pass Thru)
2027EPX (Pass Thru)
2027ENH (No Oil Tube)
2027XENH (No Oil)
Lead-In Cord P/N:
Kettle Receptacle P/N:
48290
41516E
Kettle Lead-In Cord P/N: 48290
Kettle Receptacle P/N:
41516E
2B. Electronic machines made between 1999 and 2004 w/ LEFT Hand Dump:
Domestic Item Numbers:
Kettle Complete: 2027EL (Left Hand)
Export Item Numbers:
Kettle Complete: 2027ELX (Left Hand)
Lead-In Cord P/N:
Kettle Receptacle P/N:
Kettle Lead-In Cord P/N: 48290L
Kettle Receptacle P/N:
41516E
48290L
41516E
Note Pin #6 is
Empty.
3A. Electronic machines made between 2004 and Present w/ RIGHT Hand Dump:
Models 2011E (Domestic) and 2011XE (Export) with an “E” in the model number suffix.
Also, these machines may have a numerical suffix after the model number, e.g. 2011-071.
Two (2) GOLD
Colored Pins.
Picture of 55140 Cord:
Domestic Item Numbers:
Export Item Numbers:
Kettle Complete: 2127
Kettle Complete: 2127EX
2127HT (High Top)
2127HTX (HighTop)
2127HTP (High Top Pass Thru)
2127HTXP (HT Pass Thru)
2127NH (No Oil Tube)
2127XNH (No Oil Tube)
2127P (Pass Thru)
Lead-In Cord P/N:
Kettle Receptacle P/N:
55140
55165
Kettle Lead-In Cord P/N: 55140
Kettle Receptacle P/N:
55165EX
3B. Electronic machines made between 2004 and Present w/ LEFT Hand Dump:
Domestic Item Numbers:
Export Item Numbers:
Kettle Complete: 2127L (Left Hand)
Kettle Complete: 2127EXL
2127HTL (High Top-LH)
2127HTPL (High Top Pass Thru-LH)
2127LP (Pass Thru)
Lead-In Cord P/N:
Kettle Receptacle P/N:
55140L
55165
Four (4) Large Contacts
& Four (4) Small Gold
Pin Contacts
Kettle Lead-In Cord P/N: 55140L
Kettle Receptacle P/N:
55165EX
4. Other 32 Oz. Kettle Model Numbers: For other 32 Oz. kettle model numbers not listed, contact Gold Medal Technical Support at
(513) 769-7676.
________________________________________________________________________________________________ Gold Medal Products Company | 10700 Medallion Drive | Cincinnati, Ohio 45241 | 800‐543‐0862 | gmpopcorn.com 
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