MARKET FORGE MT-40 (02) PDF MANUAL

Proceed with kettle operating procedure as follows:

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.

2. Check that Draw-Off Valve is tightly closed.

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.

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.

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.

CAUTION: 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.

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 explained below:

1. Hold the pan support in front of the upright (A).

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 (B).

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 (D).

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.

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.

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.

Care should be taken to use the smallest flow of steam, to lessen the possibility of scorching foods that caramelize at relatively low temperatures (like eggs and milk-based 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.

Key considerations:

• Estimate actual cooking capacity of Steam Jacketed Kettles at 3/4 of its volume, to allow stirring without spillage.

• Plan an adequate drain arrangement. A grated gutter type drain located in front of the kettles is preferred.

• 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.

• 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.

This chart 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)	KETTLE SIZE – 40 gallon (150 liters)
BEVERAGES
Cocoa or Coffee	6 oz or 3/4 cup (180 ml.)	Yield: 20 gal. (75 l.) Portions = 425	Yield: 35 gal. (132 l.) Portions = 745
BREAKFAST FOODS
Cereal	6 oz or 3/4 cup (180 ml.)	Amt. Raw: 20# (9 kg.) Portion = 270	Amt. Raw: 36 # (16.3 kg) Portion = 480
Scrambled Eggs	4 oz or 2 eggs each (115 g.)	Eggs: 90 dz. 18 gal. (120 l.) Portions = 540	Eggs: 160 dz., 32 gal. (166.5 l.) Portions = 960
DESSERTS
Cornstarch Pudding	4 oz. or 1/2 cup (120 ml.)	Yield: 17 gal. (64.3 l.) Portions = 545	Yield: 30 gal. (113.5 l.) Portions = 960
Gelatin	4 oz. or 1/2 cup (120 g.)	Yield: 20 gal. (75 l.) Portions = 640	Yield: 35 gal. (132 l.) Portions = 1120
MAIN ENTREES * (* All main entree figures are given in terms of raw ingredients.)
Macaroni, Beef and Tomato	6 oz. or 3/4 cup (170 g.)	Yield: 17 gal. (65 l.) Portions = 360	Yield: 30 gal. (113 l.) Portions = 640
Baked Beans	5 oz. or 2/3 cup (140 g.)	Yield: 20 gal. (75 l.) Portions = 500	Yield: 32 gal. (120 l.) Portions = 800
Beef Stew	8 oz. or 1 cup (225 g.)	Yield: 17 gal. (65 l.) Portions = 270	Yield: 30 gal. (113 l.) Portions = 480
Macaroni and Cheese	5 oz. or 2/3 cup (140 g.)	Yield: 17 gal. (64 l.) Portions = 425	Yield: 30 gal. (113 l.) Portions = 750
Turkey A La King	4 oz. or 1/2 cup (115 g.)	Yield: 17 gal. (64 l.) Portions = 545	Yield: 30 gal. (113 l.) Portions = 960
MISCELLANEOUS
Gravy/Sauce	2 oz. or 3/4 cup (60 ml.)	Yield: 20 gal. (75 l.) Portions = 1200	Yield: 35 gal. (132 l.) Portions = 2000
MACARONI AND RICE
Noodles	4 oz. or 3/4 cup (115 g.)	Amt. Raw: 20 gal. (9kg.) Portions = 220	Amt. Raw: 35 # (15.8kg.) Portions = 385
Rice	3 oz. or 1/2 cup (85 g.)	Amt. Raw: 20 gal. (9 kg.) Portions = 320	Amt. Raw: 35 # (15.8 kg.) Portions = 560
Spaghetti or Macaroni	4 oz. or 3/4 cup (115 g.)	Yield: 20 gal. (9 kg.) Portions = 320	Amt. Raw: 35 # (15.8kg.) Portions = 385
SOUPS
Basic Cream Soup	6 oz. or 3/4 cup (180 ml.)	Yield: 20 gal. (75 l.) Portions = 400	Yield: 35 gal. (132 l.) Portions = 700
Broth Type Soup	8 oz. or 1 cup (240 ml.)	Yield: 20 gal. (75 l.) Portions = 325	Yield: 35 gal. (132 l.) Portions = 560
VEGETABLES
Fresh	4 oz. or 1/2 cup (115 g.)	Amt.Raw: 80#. (36.3kg.) Portions = 335	Amt. Raw:120 # (54.4 kg.) Portions = 500
Frozen Loose Pack	4 oz. or 1/2 cup (115 g.)	No. Of Packages: 50 Portions = 550	No. Of Packages: 80 Portions = 880
Frozen Solid Pack	4 oz. or 1/2 cup (115 g.)	No. Of Packages: 25 Portions = 275	No. Of Packages: 40 Portions = 440

The most important preventive maintenance operation on the steam jacketed kettle is the daily cleaning procedure after each use. All kettle cleaning procedures should be faithfully completed by the end of each day’s operation. In addition, cabinet doors, top, fixtures, 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.

3. Loosen food which is stuck to kettle by allowing it to soak. Also, a small amount of steam may help.

4. Position swing drain under draw-off valve. Open draw-off valve to drain soapy water.

5. Wipe down exterior, rinse and dry. Avoid getting water into electrical controls.

WARNING: 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 counter-clockwise until valve handle and stem are free.

8. Wash inside of draw-off valve with a nylon brush.

9. Rinse kettle valve interior and reassemble valve.

NOTE: Leave draw-off valve open when kettle is not in use.

10. Remove swivel drain and its strainer. Wash, rinse and replace.

In addition to the daily cleaning it is necessary to clean the air intakes on a weekly basis. Air intakes provide necessary cooling air to the internal components. They are generally located on the rear and sides of the equipment.

Lubrication of the tilting mechanism is the only required preventive maintenance other than daily cleaning.

1. Inspect the screw of the tilting mechanism annually for adequate lubrication.

2. If screw appears “dry”, apply good grade bearing grease directly on the threads so that the threads appear to be barely damp.