Productivity

Anyone purchasing an industrial dishwasher has a specifi c purpose: TO WASH LARGE QUANTITIES OF DISHES IN THE SHORTEST POSSIBLE TIME. When you choose a machine and consult the sales brochures of various manufacturers, you will see that the fi gure most often quoted is the

Theoretical productivity
This value does not refl ect the real-life use of the machine as it only takes into account the shortest wash cycle; for example, a dishwasher with a 60” cycle will have a theoretical productivity of 60 racks (1080 dishes) per hour. However, in reality, a cycle can never be shorter than the recovery time determined by the thermostop, i.e. the time taken by the boiler to bring the water up to the correct temperature for rinsing. The recovery time for any type of dishwasher can be calculated using a simple formula from the following parameters: rinse temperature, water supply temperature, boiler power and water consumption per cycle. 

For example, given a rinse temperature of 80°C, a water supply temperature of 15°C and 6kW boiler, the recovery time will vary as follows according to the water consumption per cycle: 136” for 3 litres, 113” for 2.5 litres, 91” for 2 litres. So, the machine you bought thinking it was capable of washing 1.080 plates per
hour will in reality only be able to wash between 468 and 702, which is 57% to 35% LESS.

Sales brochures often contain phrases of the type “Important: the Thermostop may reduce productivity if the water supply temperature is less than 50 °C”, which may serve to justify this shortfall, but fail to give an idea of what sort of productivity the user might reasonably expect to achieve.

Practical productivity
This fi gure takes into account the recovery time required to unload and load the machine between cycles and is an indication of the maximum productivity that can be obtained in the best real-life operating conditions when
several cycles are performed in succession. Colged provides this information based on a water supply temperature of 15°C (as the majority of installations run on cold water) and an average load/unload time of 10”.

Colged productivity
The new generation of Colged dishwashers has been designed to offer the highest real-life productivity thanks to the application of technologies to shorten the recovery time, particularly by reducing water consumption. Shorter wash cycles mean higher temperatures are needed to obtain good results, and for this reason our new dishwashers use an electrical power division system, with total consumption always below 16 amp, and an effective tank temperature that is 10°C higher than previous generation machines in the case of repeated washes. We are therefore able to offer dishwashers with a practical productivity ranging from 45 to 50 racks/hour, depending on the model. These are absolutely the highest values on the market for the respective product classes. Furthermore, to reduce the time needed to prepare the machine at the start of the work shift, we offer QuickReady technology, which utilises all the available electrical power to heat the tank water.

Operational flexibility

Space is a valuable resource in any kitchen, and this is why Colged has created truly multifunctional dishwashers that are able to fulfi l a variety of very different functions as the need arises. All our under-counter machines have three standard programmes for dishes, up to three programmes for self-cleaning and tank water changing and up to seven specialised programmes. All machines offer the automatic start function, where the cycle is started simply by lowering the hood.

Standard programmes
Differ not only for their contact time (cycle duration), but also for their wash and rinse temperatures and water consumption. Each programme is designed for a specifi c purpose: ProSpeed: for fresh, light soiling; ProFessional: for general use; ProTemp: high temperature wash for heavy soiling.

Specialised programmes
Can transform a plate washer into a glass washer, into versatile small utensil washer, into a cutlery washer and even into a machine for sanitization to current European standards. ProGlass: for glass and crystal; ProWater: special programme for osmosis water; ProActive: with automatic prewash for heavily soiled pans and dishes; ProSteel: for steel cutlery; ProSan: sanitization to EN ISO 15883-1/3; ProEco: low temperature wash for blood and starch; ProLong: continuous wash for dried-on dirt.

Self-clean programmes
These programmes simplify and speed-up end-of-shift operations and allow rapid changeover of all the water contained in the wash tank. Depending on the model and the version, the machine may offer up to three programmes of this type.

ProSelf: self-clean cycle for machines with gravity drain; ProNew: total water changeover; ProClean: self-clean cycle with high-pressure jets for machines with EvoLution draining; ProDrain: automatic tank draining.

Rack dimensions
The Colged product range comprises models with the traditional 50 x 50 cm rack capable of accommodating 18 standard plates, and also models with a 60 x 50 cm rack that can take 22 plates. Special racks are available for trays and glasses, with both flat and sloping bases, with and without separators and with different heights, which can be used to both wash and store glasses.

Hood opening width
Operational flexibility is enhanced by the ample opening width of 45.0 cm for the SteelTech and IsyTech, models, and 46.5 cm for he TopTech model, which is wide enough to accommodate Gastronorm and Euronorm trays as well as miscellaneous utensils and smaller pans. These are highest values available on the market for the respective product classes.

The service table system
Colged offers an ample choice of service tables and accessories, the majority of which may be used with any of our ranges and models, to create a work area precisely tailored to suit the needs of the user and the space available. The machines can installed in-line or as corner units without the need for additional components, and the height of the entire machine/table system from fl oor level can be adjusted for optimum ergonomics.

Easy cleaning

Colged dishwashers are constructed in accordance with the TotalClean design philosophy to make end-of-shift cleaning operations as quick and easy as possible. This entails a number of important design features:

Construction
No pipes inside the wash chambers, stainless steel rack guides, unblockable integral surface strainers, with 2.5 mm diameter mesh and dish-shaped to trap dirt during emptying. The hood is constructed with three movable sides and one fi xed so as to convey the vapour towards the rear, thereby ensuring that the operator is not engulfed in a cloud of steam when the hood is opened.

Functionality
Progressive triple-stage fi ltration of the tank water with elimination of particles
down to a diameter of 0.8 mm; programme for self-cleaning of the wash
chamber; wash arms with the EasyHandling system, which means they can
be removed simply by pressing a button and then clicked back into place.

Lower operating costs

Reduced costs for water, electrical power and chemicals are an immediate benefi t for users of Colged dishwashers. The cost of washing 1800 plates (100 standard racks) ranges from 5.29 to 6.46 €, according to the model; the lowest costs in their product category. The operating cost depends greatly on water consumption, of which the greater part occurs during the rinse cycle. Colged has conducted its own research into the reduction of water consumption: even 10 years ago our TopTech dishwashers had a water consumption of just 1.9 litres cycle, when the majority of our competitors could do no better than 2.5 litres. Thanks to the use of new technologies, such as the HiTech spray arm and UltraRinse3 geometry, our dishwashers can now offer a water consumption
of just 1.6 litres per cycle (TopTech 38-23), a reduction of over 15%.

For the other models in our range, water consumption is between 1.8. and 2.0 litres per cycle, equivalent to a reduction of between 22 and 25%. By way of example, the table below shows the comparative costs for washing 1800 plates (100 standard racks) for various levels of water consumption, with a water supply temperature of 15 °C.

Some models feature the EnergySaving function which decreases electrical power consumption during stand-by periods by reducing the boiler temperature to the lowest possible value that allows return to the preset temperature for the selected programme before rinsing.

NRG models are equipped with an effi cient system that recovers heat from the steam produced during the wash and rinse cycles, thereby signifi cantly reducing energy consumption.
* Costs used: water 2.0 C / m3, energy 0.17 C / kWh, detergent 3.75 C / kg, rinse aid 4.5 C / kg.

The Technologies

Water distribution system

The main component is the HiTech arm made from a composite material called ProComposit (30% fi breglass, 30% talcum microparticles, 40% organic resin). During rinsing, patented UltraRinse3 geometry ensures that the water is used more effectively and effi ciently, thereby helping to minimise consumption. The washing nozzles are at the same level as the rinse nozzles; this means that the spray is not obstructed, as is the case with the normal arrangement of separate wash and rinse arms. The arm rotates on 3 graphite bearings which reduce friction to virtually zero; this means the full force of the water from the pump is applied to wash the dishes rather than to rotate the arm via the reaction holes.

Th HiTech arm features a snap-fit attachment system, which makes it easy to install and remove for cleaning, even with just one hand. Its mechanical strength, elasticity, resistance to chemical attack and simplicity of cleaning make this component particularly effective.

Washing system

The heart of the system is the powerful pump with patented DuoFlo technology. Thanks to the pump’s two outlets, with one outlet connected directly to the upper arm and the other to the lower arm, this system eliminates the loss of pressure caused by dividing the fl ow; in this way all the energy absorbed is transferred to the water, thereby achieving an effect equivalent to a conventional pump 25% more powerful. This means the same level of performance for a much lower electrical power consumption.

A shorter wash cycle, with lower water and detergent consumption, is possible only with a higher wash temperature. Unfortunately, the majority of products on the market have tank and boiler heating elements that function alternately, with priority given to the boiler for reasons of hygiene. This means that, with repeated cycles, the tank is not heated suffi ciently and its temperature falls rapidly, thereby compromising washing results. On the new Colged dishwashers, the HotWash system instead shares the electrical power between two independent heating elements
so as to allow numerous repeated wash cycles and constant heating of the tank. The result, compared with a machine with interlocked heating elements, is that the temperature is around 10 degrees higher during repeated wash cycles: this allows a shorter wash time and a shorter drying time as the plates get hotter, lower detergent consumption and consequently lower costs.

With the ProDose system, detergent products are dosed by an electronically-controlled peristaltic pump, which can be easily adjusted from the control panel, and which ensures constant, precise dosing of detergent and rinse aid without any wastage. On request, the machine may be equipped special level sensors that signal via a message on the display when the detergent tanks need to be changed, thereby avoiding the risk of the dosing units being damaged by running empty.

Rinse systems

Colged dishwashers employ a number of different rinsing systems, with different levels of complexity and performance, each of which however is capable of ensuring that certain parameters remain constant:

Timed rinse: uses ThermoStop to ensure a constant temperature at the start of the rinse cycle; the duration of the cycle is fi xed, while the water consumption level depends greatly on the pressure of the mains
water supply. It is used on the models 38-00 -10 -20. The minimum water consumption is 2 litres/cycle.

Volumetric rinse: uses ThermoStop to ensure a constant temperature at the start of the rinse cycle; the duration of the cycle is variable and depends greatly on the pressure of the mains water supply; the average
water consumption is constant and independent of the supply pressure. It is used on the models 38-01 -11 -21. The minimum water consumption is 2 litres/cycle. 

ProRinse system: ensures that the initial and average rinse temperatures, the fl ow rate, the pressure and the duration all remain constant. All the physical parameters that determine optimal rinsing are controlled and managed, and this why it is possible to get consumption down as low as 1.6 litres/cycle and achieve constant results, regardless of the characteristics of the water supply. The water is supplied via a beak tank, which conforms to WRAS anti-pollution standards, a non-pressurized boiler and a rinse water suction pump. It is used on the models 38-02 -03 -12 -13 -22 -23.

Filtration systems

Colged dishwashers are equipped with two systems for fi ltration and drainage of the wash waster with different degrees of complexity: 

ArchiMedes – A patented system that exploits the principle of communicating vessels to ensure that the dirtiest water at the bottom of the tank is the fi rst to be drained under the pressure of the cleaner water above. This simple but effective device raises the effi ciency of the water changeover from the 66% generally obtained with a conventional overflow drain, to 83%; the result is cleaner water in the tank, with the possibility to reduce the amount of water used in the rinse cycle and the concentration of detergent used. It is used on the models 38-00 -02 -10 -12 -20 -22.

EvoLution3 – A complete and effective system which uses 3-stage water filtration with progressively decreasing mesh size down to 0.8 mm. The water is drained from the bottom of the tank by a specifi c pump and drainage takes place after washing and before the start of the rinse cycle. This makes for a 100% effi cient water changeover and maximum cleanliness of the water in the tank. It is used on the models 38-01 -03 -11 -13 -21 -23.

In both systems surface fi lters are used (either in steel or composite material depending on the model) that extend the full width of tank and are therefore virtually unblockable. We can therefore do without the filter presence sensors or clogging sensors used on many of our competitors’ models as they serve no purpose.

Water treatment systems

Certain models can be equipped with the built-in CareFree continuous water softener. The continuous water softener automatically performs regeneration during every wash cycle; the only action required of the
operator is to top up the salt when requested by a message displayed on the screen of the user interface.

In addition to built-in systems, Colged also offers large-capacity external water softeners, in both manual and automatic versions, decarbonation systems and reverse osmosis fi ltration system to obtain water that is
perfectly purifi ed; osmosis water is especially recommended for washing crystal glasses and cutlery, but has no advantages for washing dishes.

NRG heat recovery system

At the end of the wash cycle, the steam in the wash chamber is aspirated through two vents in the back panel and directed to a heat exchanger made from copper and aluminium (or optional stainless steel for machines supplied with osmosis water) where the steam gives up its latent heat of evaporation to the cold water coming from the mains, which is then sent to the boiler. The steam condenses and is expelled, while the temperature of the cold water rises by approximately 20°C. The entire process takes only 30”, which must therefore be added to the standard duration of the wash cycle.

The clear benefi t of the NRG system is that water vapor is not emitted into the environment, in other words, the recovery system performs a function that otherwise would have to entrusted to an extractor hood.

The economic impact, however, is signifi cant: if 100 cycles per day are performed with the ProFessional programme, the daily saving would be 4.2 kwh; this means that it is possible to save 260 € on your electricity bill in just one year.