Envac kitchen waste vacuum system profitable, hygienic and increased accessibility
Hygiene and environmental health and safety The commercial preparation of food is a rapidly growing and competitive industry and wherever food is handled, waste is produced. Changing habits... As the pace of society quickens, it leaves less time to spend on cooking for ourselves. In today s modern world we demand instant access to meals at all times of the day and want locations nearby too. We also demand high quality in both hygiene and service. The variety of food is increasing, which means that we now have to handle and process raw materials that were not even thought of a generation ago.... lead to new requirements An ever increasing numbers of facilities for the commercial preparation of meals and a very competitive industry. Problems with conventional handling include: waste bins and containers adjacent to food preparation lead to hygiene problems large air-conditioned waste storage rooms take up valuable space and consume energy collection, separation and storage of waste are causing logistical issues and occupational health & safety hasard manual waste transportation paths in the kitchen take up too much space and cause health and safety issues in congested areas of the kitchen regular cleaning of bins and waste storage rooms is time-consuming, expensive and unhygienic
challenges for kitchen waste handling One of the more central aspects of all commercial meal preparation processes is the waste handling process. Wherever food is handled, waste is produced. Kitchen waste creates hygiene risks wherever it is transported or stored. The internal handling of kitchen waste is a time and cost consuming operation. On the other hand, kitchen waste correctly handled and processed is an important environmental resource. new insights Planners, developers and architects need to consider these growing demands in the location and design of commercial kitchens. They also need to find solutions which make the kitchen operation as efficient as possible, using both space and labour in the most productive way. t Food waste is one of the most important renewable energy resources in the world. Because of stringent environmental requirements we are expected to: minimise waste quantities and reduce bulk separate waste handling physically from other activities prevent any growth and spread of microorganisms to food, dish ware, glassware, utensils and people treat organic waste as a biological resource 1
A solution should be sustainable both from an Spotless waste handling MaxiVac and MiniVac are two systems from Envac that are based on the principle of hermetically sealed storage and vacuum transportation of kitchen waste. Manual waste handling is a distant memory we let the air do the hard work! This unique technology does away with all manual handling and transportation of kitchen waste. The waste is disposed of in centrally and conveniently located disposal inlets. The inlets are connected to a pipe system through which the waste is removed from the kitchen premises by vacuum. The pipe system ends in a collection station where it is automatically transferred into tanks or containers, which are easily collected or emptied by conventional vehicles. The process is monitored by computer, and efficiency and performance of the system can be constantly measured. Unlimited applications Kitchens require a work environment that is hygienic, user friendly and with good accessibility. Our kitchen waste systems can be applied in both small and large professional kitchens. Applications for the technology are practically unlimited, regardless of the design and function of the kitchen premises. u In total Emirates Flight Catering in Dubai, has more than 6,000 employees who produce an average of 95,000 meals per day for passengers travelling on around 300 different flights. 2
environmental and an economical perspective Hermetically sealed and environmentally friendly The systems are hermetically sealed, which improves the hygiene in the kitchen and prevents the spread of odours, and eliminates traditional problems associated with insects or pests. They provide a safe and comfortable working environment for both the kitchen staff and the waste collectors. Both the organic component and the packaging part of the waste can be separately stored, transported and processed into new resources. p Loose and bagged waste fractions are transported by vacuum through hermetically sealed pipe systems. t The inlets are ergonomically designed and facilitates the daily operation. 3
Great improvements in hygiene, ergonomics, Improved hygiene in food preparation, dishwashing, waste transportation and storage are just a few of the advantages of the Envac system when compared to traditional waste collection. No cross-contamination The system separates food preparation from the storage of waste; which greatly reduces the risk of cross contamination. No microorganisms nor bacteria are spread through the waste. We offer different inlets and solutions depending on the hygiene zones; the staff can stay and work in their specific zone. Improved ergonomics and accessibility The waste inlets are placed close to where the waste is created. The vacuum process takes the waste away from the point of production to the chosen collection location, usually in a basement or service yard. Benefits hygienic and ergonomic Increased hygiene. There is no cross-contamination, the waste is immediately removed from food preparation. Sealed systems. No odour, no leakage, no bacteria. Better ergonomics. Through the elimination of manual handling and transportation of food waste. Self sanitising. The system effectively cleans itself. ISO 14001 certification of your kitchen. HACCP-compliant with the most stringent hygiene requirements. 4 p Buffer carousel (BF) designed for bagged waste for storage of six waste bags.
... economy, logistics and environment Economically beneficial investment The system releases valuable space in the kitchen. The accessibility improves and the accident levels decrease. It simplifies kitchen routines, and eliminates the need for internal handling of waste and cleaning of waste storage rooms. The system operates with high air speeds so the pipe system is practically self cleaning. The system also helps achieving the ISO 14001 certification of your kitchen. Food waste recycling Our system leads to energy savings, since air-conditioning of the storage room is unnecessary. The purity of the collected organic waste is ideal for biogas production. We offer optional processing of the waste (grinding, de-watering, etc.) in order to achieve a consistency suitable for further handling. Benefits Economic, logistical, environmental Durability a sustainable waste solution. Profitability increases efficiency of labour, eliminates heavy, dirty and time-consuming manual handling. Area efficiency no traditional waste bins releases valuable space. Logistic our system enables efficient kitchen design. Optimises system capacity with regard to anticipated waste quantities and collection frequencies. Optional processing of the waste in order to achieve a consistency, suitable for further handling. Sorting and recycling the process can be planned to improve sorting and recycling of waste. 5
MaxiVac for large amounts of kitchen waste day and night A MaxiVac waste system can range from a basic tray-stripping configuration up to an advanced installation handling all categories of waste in the kitchen. Typical applications are flight catering facilities, industrial food factories, and large kitchens with a high throughput. MaxiVac is designed for large catering kitchens, which are in service 365/24/7. MaxiVac has the capacity to rapidly handle large amounts of waste. p Integrated inlet for loose food waste. u Buffer carousels with six inlets handles large amounts of bagged waste and are emptied automatically when full. 6
from meal preparation and dishwashing areas The system is used for the efficient removal of all types of organic and solid waste in meal preparation and dishwashing areas. Employees can do all their work in a single area, which improves hygiene and saves time. The system can easily be adapted and combined in many different ways to suit widely varying requirements. p The cyclones for two parallel systems mounted on a mezzanine floor located above the compactors. The cyclones separate the waste from the air. z The Emirates Flight catering kitchen has nine tray stripping lines, that together handles over 115 000 trays a day. tt Tray stripping line with a Tray Waste Inlet at Addis International Catering in Ethiopia. t Interior from Korean Air in Seoul, showing Tray Stripper Hood, removing loose waste with vacuum. 7
How MaxiVac works Typical inflight catering design 1 Dedicated inlets are placed in the differ- pipe system. The waste is transported ent hygiene zones in the production area by a rapid air stream to the waste sepa- for immediate disposal of loose food waste and bagged mixed waste. The dishwashing area can have partial rator and transferred automatically into the compactor. It can also be transported directly into the waste container. The 2 3 or fully automatic disposal of waste from containers are emptied one at a time trays and meal boxes. without interrupting the operation of the The inlets are connected to the waste system. room by means of a completely sealed Different inlets 1. Screw Feeder in Bench, SF, placed in working areas designed for loose food waste and used together with open bins like in vegetable preparation areas. 2. Buffer carousel, BF, for storage of six wastebags. These inlets are capable of handling multiple bags in special dedicated sub waste rooms strategically located, designed for bagged waste. 3. Trash Chute in Bench, TCB, to be placed in pot wash areas where wet and loose food waste is created. 4. Tray Stripper Hood, TRS, for continuous removal of waste from trays using vacuum. Direct removal on the tray conveyor saves operators and time. 5. Tray Waste Inlet, TWI, for the collection of tray waste from returned trays which is dropped into a hopper for intermittent suction, several inlets can be connected to the same suction system. 6. Trash Chute in floor, TC, for bagged and bulky waste which easily can be removed by hand from the tray waste conveyor. Collection station A Vacuum unit B Filters C Cyclones C 4 D Waste diverter E Containers D B A E 8
Food production area Integrated and freestanding inlets for food waste and bagged mixed waste Food waste pipes (green) 200 mm Bagged waste pipes (orange) 300 mm 5 6 Warewashing area Integrated and freestanding inlets for bagged and loose waste Bagged waste pipes (orange) 300 mm Loose waste pipes (blue) 200 mm 9
MiniVac removes food waste in large kitchens The MiniVac system is designed for manual in-feed of food waste from meal production and dishwashing areas. Typical applications are restaurants, food courts, food markets, canteens in hospitals, offices, universities, industrial and larger kitchens. Easy applicable and improved hygiene The system is ideal for both retrofitting existing kitchens and for new construction. Waste disposal inlets are conveniently integrated in the workflow, improving the use of valuable space and freeing it up for profit-generating activities and at the same time improving ergonomics. Cross contamination can be avoided as the system immediately separates kitchen waste from food production. The system can also turn your waste problem into a valuable resource e.g. through the production of biogas. p A flexible food waste inlet module from Envac in a kitchen operation. u Special designed trash chutes in dish washing areas. 4 uu End product stored in tanks in fluid form suitable for biogas production. uuu The containers are collected by conventional hooklift trucks. 10
How MiniVac works A typical MiniVac installation The operators fill up the storage section. A simple touch initiates the waste transportation by intermittent vacuum. The waste is transported to a tank where it is stored. The tank is optimised for biogas production or composting, a suction vehicle will soak up the residue. The waste can also be stored in a mobile container. 1 1 1 2 1 3 4 5 6 Benefits with MiniVac Easy application No cross-contamination 7 Increased hygiene. Hermetically sealed system. Better ergonomics. Food production and dishwashing 1. Inlets 5. Cyclone 2. Pipes 150 mm 6. Shredder 3. Vacuum unit 7. Storage tank 4. Filter Gives higher DS (dry substance) and more food waste slurry per litre. Self cleansing. ISO 14001 certification. HACCP-compliant Recovery of biogas/fertiliser possible 11
Kitchen waste handling applications Kitchen waste is generated in many industrial processes with different processing demands. Common for all of these applications though are the hygienic handling requirements. The complete separation of the waste flow from all other handling processes is the only sustainable way to minimize the risk of crosscontamination. Envac offer automated kitchen waste systems for large and small professional kitchens. Envac s systems are virtually unlimited in their applicability, irrespective of the design of the food preparation facilities and their operation. Envac the optimal waste handling solution for: Flight kitchens Restaurants Food malls and food markets Canteens in offices, hospitals, schools, etc. Industrial food factories 12
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Envac s commitments are based on 50 years of experience Our experienced staff assists you in choosing the optimal waste handling system for your project. We take full responsibility for our installations, from the initial design and function to installation. We can also make sure that our installations run smoothly, year in and year out through our operation & maintenance offerings. Our competence is based on over 50 years of experience with the installation of systems for the pneumatic transportation of waste and recyclable fractions. We put special emphasis on the ethical behavior of our staff through our code of conduct. Correct behaviour, respect and tolerance are necessary ingredients in an internationally expanding organisation such as ours. We have our own offices in over 20 countries and specialists in kitchen waste handling in many of them. Our Business Concept We offer efficient and environmentally friendly systems for waste collection. We provide strong support during the planning, installation and operation of our systems. This will guarantee the systems to be designed to the correct specification and also with the flexibility required to meet the needs of our customers. Our aim to be considered a reliable long-term partner offering first class quality products and service. 14
... and our high customer quality demands We offer the following services in connection with the installation and use of our products Feasibility studies for larger projects We provide you with alternative cost assessments, environmental assessments and where applicable also financing advise. Turnkey installations We take the full responsibility for the entire installation from the planning board to the actual installation and operation. Training of users and service staff Correct training ensures the system is used to it s maximum potential, ensuring a satisfying result for our customer. Service and maintenance We make sure that wear and tear doesn t turn into a major problem. With our service 365/24/7 we will make your system last. That s why we still have systems in operation that were commissioned over 40 years ago and are still going strong. Quality solutions: We supply according to ISO 9001. Our systems support the certification of ISO 14001 and other environmental and hygienic standards. Our experience and work ethos ensure quality systems are delivered and maintained. We are willing to share our experience from our vast number of successful reference installations. 15
Some of our kitchen waste references Liseberg amusement park, Gothenburg Staff canteen at Astra Zeneca, Sweden Cara Airport Service, Toronto The Envac kitchen waste systems have been installed in 18 countries throughout the world. We have delivered systems for flight catering, railway catering, staff canteens, food markets and catering restaurants. Together our over 50 waste systems handle nearly 600 of ton kitchen waste per day. The map shows some examples of our project at the world largest airports and professional restaurants. Torget Fish market, Bergen Cara Airport Service, Vancouver Gate Gourmet, London Kg waste per day handled with a kitchen waste system from Envac Cara Airport Service, Montreal Kg waste/day 600 000 500 000 400 000 300 000 British Petroleum, London 200 000 100 000 0 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 European Investment Bank, Luxembourg 16 Lufthansa Sky Chefs, Rome Staff Canteen, Belgrade
Korean Air Catering, Seoul Flight Kitchen, Tokyo Asiana Catering, Seoul KSC, Osaka Östermalmshallen, Stockholm Heron City, Stockholm Ericsson Hause, Gothenburg Kiev Flight Catering Iran Air, Teheran China Oil & Gas, Beijing Beijing railway catering Seoul Fish market Air Catering, Nagoya Oberoi Flight Service, Delhi Qatar Airways Sky-Orix, Qatar Cathay Pacific Flight Kitchen, HongKong Bangkok Air Catering Thai Airways, Bangkok China Southern Catering, Guangzhou Shanghai Eastern Air Catering, Nanjing and Shanghai Oberoi Flight Service, Mauritius Qantas Catering, Sydney Malaysian Airlines, Penang Addis International Catering, Addis Abeba Emirates Flight Catering 1 & 2, Dubai Jubail Market, Sharjah, Dubai
We have offices in the following countries. For detailed contact information, please visit www.envacgroup.com ABU DHABI BRAZIL CANADA CHINA DENMARK DUBAI FRANCE INDIA ITALY KOREA MALAYSIA NORWAY PORTUGAL QATAR SINGAPORE SPAIN SWEDEN THE NETHERLANDS UNITED KINGDOM ENVAC HEAD OFFICE ENVAC AB, Fleminggatan 7, SE-112 26 Stockholm, Sweden Tel: +46 (0)8 785 00 10 info@envac.se, www.envacgroup.com Bumling AB, 06 2011