Pre–Mix
Parameters
Basic
Training
IMI Cornelius Inc.
One Cornelius Place
Anoka, Minnesota 55303-6234
1–800–238–3600
Mission Statement
To present to you… A program outlining the basic
parameters of pre-mix systems and their application. To
further enhance your sales and technical competence and
to create within, an atmosphere allowing you to become,
The Preferred Fountain Consultant, to your customers.
The Process
Uncover
D Why it is important for you to know and
understand the technical parameters and
basic application of pre-mix systems.
Discover
D Information input to build and reenforce
your working knowledge of pre-mix
systems allowing you to become of more
value to your company and customer base.
Recover
D Let you know… you know! Becoming
consciously competent.
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TABLE OF CONTENTS
PAGE
CO2 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
CO2 REGULATOR PRIMARY AND SECONDARY TYPES . . . . . . . . . . . . . . . . . .
2
PRIMARY VS. SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
IDENTIFICATION OF SPRINGS IN REGULATORS . . . . . . . . . . . . . . . . . . . . . . . .
6
REPAIRING CO2 REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
WHAT’S IN SOFT DRINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SWEETENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
DIET SOFT DRINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
CARBONATION RETENTION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
A DISCUSSION OF CO2 BOOSTER PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . .
13
EQUILIBRIUM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
OPERATING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
LESS THAN EQUILIBRIUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
OVER EQUILIBRIUM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
CHANGING PRODUCT VOLUMES OF CO2 GAS . . . . . . . . . . . . . . . . . . . . . . . . .
18
TESTING VOLUMES OF CO2 GAS IN CARBONATED BEVERAGES . . . . . . . .
19
SANITIZING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
SANITIZING SPECIAL EVENT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
SANITIZING JUMPERS AND GAS LINE ASSEMBLIES . . . . . . . . . . . . . . . . . . . .
22
EQUIPMENT REQUIRED FOR SANITIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
STANDARD PRE–MIX DISPENSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
BAR VALVE – FIVE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
CO2 CYLINDERS
1. Handle with care.
A. Damaged CO2 cylinder can become an unguided missile.
2. Keep it upright.
A. Prevent liquid CO2 from entering system.
3. Open valve all the way.
A. Valve has upper seat for open position and lower seat for closed position partial opening
may permit leak or loss of CO2 and result in service call.
4. WARNING - Overfilling is dangerous. Allow only properly trained personnel to fill cylinders.
A. Dry weight is stamped on cylinder. Add only specified amount of liquid CO2, then check
weight.
5. When empty, keep valve closed.
A. Prevent air entering, as it could lead to condensation and corrosion resulting in formation of
scale inside cylinder.
6. Cylinder must be inspected every 5 years
A. D.O.T. Regulation requires this - inspection date is stamped on cylinder your CO2 supplier
can inspect them or direct you to someone who can.
B.
This is the responsibility of the owner of the cylinder.
C.
Painting neck of cylinder different colors help identify year of purchase and year inspection
is required.
7. Each pound of liquid CO2 will propel approximately 10 gallons of product.
8. Before filling CO2 cylinder, invert cylinder in a rack designed to hold it securely and open valve to discharge
CO2 gas. This will also remove any water, loose scale, and sludge from the cylinder.
9. Safety disc in CO2 cylinder valve will rupture between 2600 and 2975 psig.
A. Normal service operating pressure maximum is 1800 psig.
B.
Install only one safety disc.
C.
Each manufacturer has a safety disc for his valve.
10. Do not interchange parts between valves manufactured by different companies. This includes safety discs.
1
SD 107
CO2 REGULATOR
PRIMARY AND SECONDARY TYPES
1. Reduces pressure to operating pressure. (Single stage reduction)
A. High pressure side - inlet pressure from CO2 cylinder or primary regulator.
B.
Low pressure side - regulated pressure for use as operating pressure on product tanks
a.
High and Low indicated on back casting of regulator.
CAUTION - DO NOT MAKE OPERATING PRESSURE CONNECTIONS TO HIGH SIDE.
2. Handle with care - treat as precision instrument.
A. Storage - on shelf or hang it up.
B.
Back out adjusting screw.
a.
When disassembling.
b.
When not to use is.
3. Various combinations.
A. End mount, center mount, and wall mount (with bracket).
B.
2 pressure 2-3-4 flavor For use with tanks containing products with different carbonation
levels.
3. pressure 3-4-5 flavor For use with tanks containing products with
different carbonation levels.
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2
4. Cornelius exclusive Bleed-O-Matic or self-bleeding.
A.
Will not rupture diaphragm by reducing set pressure. It is not necessary to bleed downĆ
stream pressure as others require.
B.
To reduce pressure, back out screw to approximately 15 psig below desired pressure and
then advance setting to desired pressure to obtain true setting. With 40 psig desired, back off
to 25 psig and advance to 40 psig.
5. Integral relief valve.
A.
Approximately 12 psig differential between set pressure and relief.
6. Won't creep.
A.
Relief system will vent at approximately 12 psig above set pressure.
7. Positive check valve.
A. Check valve must be installed for each gas line.
B.
Prevents products from backing up through gas lines and mixing.
C.
Prevents product backup into regulator.
8. Leak detection.
A. External leak - listen for it - use soap solution on manifolds, etc.
B.
Internal leak - put finger over orifice in cover and watch for pressure rise on low pressure
gauge.
C.
Small internal leak - soap solution over orifice in cover will result in bubbles.
9. Repair and maintenance.
A. Repair kit will completely rebuild - shop or field repair (see repair outline).
B.
a.
Use 3/4 inch wrench to replace poppet.
b.
Use screwdriver to replace diaphragm assembly.
c.
Replace main seat. Tools required are 3/4 inch wrench, screwdriver, 3/8 inch diameter
wooden dowel and small hammer. Main seat is no part of repair kit.
On fairly new regulator, replace only part that malfunctioned. Visual inspection will norĆ
mally disclose part or parts that should be replaced.
a.
Date of manufacture is stamped on side of casting.
C.
On old regulator, replace all parts contained in repair kit (see repair outline).
D.
Damaged or inoperative gauges should be replaced; repair is impractical due to low cost of
gauge.
3
SD 107
10. Pressure indicated on high pressure gauge of CO2 regulator when ambient temperature is as listed below
and CO2 cylinder still contains liquid CO2 .
SD 107
Below 40 degrees
550 psig approximately
40 – 48 degrees
600 psig approximately
48 – 60 degrees
700 psig approximately
60 – 70 degrees
820 psig approximately
70 – 80 degrees
960 psig approximately
80 – 90 degrees
1150 psig approximately
90 – 100 degrees
1400 psig approximately
100 – 120 degrees
1825 psig approximately
4
PRIMARY VS. SECONDARY
1. All regulators look exactly the same.
A. Identified by decal on cover.
2. Primary attaches directly to cylinder valve - minimum inlet pressure is 500 pounds.
A. May wander or leak internally below that pressure.
3. Secondary receives inlet pressure from primary - maximum inlet pressure is 300 pounds.
A. Used to "fine tune" or where CO2 cylinder can not be located near product tanks.
B.
300 pounds or more - destroys rubber seat - may blow up regulator.
4. Springs and screws identical to primary.
5. Components differ - secondary has larger main seat, rubber seat, stem in diaphragm assembly, and guide.
A. Larger area for lower incoming pressure to "push" against and seal properly.
6. Two different repair kits: 18-3065 - primary 18-3099 - secondary
5
SD 107
IDENTIFICATION OF SPRINGS IN PRIMARY OR
SECONDARY REGULATORS
30 pounds - blue
60 pounds - black
100 pounds - silver
160 pounds - gold
1. All adjusting screws are identical in length.
A. Do not use longer screw to obtain higher pressures - destroys internal relief feature.
B.
SD 107
Use proper spring to match gauge on low side
6
REPAIRING CO2 REGULATOR
Caution: Be sure only proper repair parts are used. Do not substitute parts from a manufacture for
those of another manufacture.
1. Disassembly.
A. Back off adjusting screw to relieve tension of adjusting spring.
B.
Remove cover screws, cover spring retainer, adjusting spring, diaphragm
assembly, baffle guide, and baffle gasket.
C.
Remove cartridge plug with filter screen, o-ring, poppet spring, and poppet assembly from
opposite side of regulator body. Discard poppet assembly and o-ring.
D.
If main seat must be changed, use 3/8 inch diameter (wooden or plastic)
dowel to tap seat from regulator body from cover side. Do not use
screwdriver or metal punch.
Note: Main seat is not included with repair kit - it must be ordered separately.
E.
Wash regulator components with warm water and mild detergent.
2. Re-assembly.
A. If main seat is replaced, install new seat gasket in regulator body. Carefully press or use 3/8
inch diameter wooden dowel to tap new main seat into place in regulator body. Position
new poppet assembly in main seat. DO NOT TOUCH SEATING SURFACES OF MAIN
SEAT AND POPPET ASSEMBLY.
B.
Assemble cartridge plug with filter screen, o-ring (new), and poppet spring. Screw cartridge
plug into regulator body.
C.
Install guide (new) in baffle. Place baffle gasket, baffle, guide assembly, diaphragm assemĆ
bly, adjusting spring, spring retainer, and cover on regulator body. Secure with cover screws.
D. Install adjusting screw in cover.. Note: New assemblies will not allow removal of adjusting
screw.
7
SD 107
WHAT'S IN SOFT DRINKS
Soft drinks have been part of the American lifestyle for more than 100 years. Many of today's soft drinks are the
same as the first ones enjoyed in the 1800s.
Soft drink production begins with the creation of a flavored syrup using a closely-guarded company recipe. The
syrup is mixed with purified water and the carbonated by adding carbon dioxide gas under pressure. This carbonĆ
ation creates the "tingly fizz" that gives soft drinks a refreshing taste.
Now for a closer look at soft drink ingredients.
Like other foods, the ingredients that are used in soft drinks are approved and closely regulated by the U.S. Food
and Drug Administration (FDA). All of the ingredients used in soft drinks are found in a variety of other foods.
Water
Bottlers use sophisticated filtering and other treatment equipment to remove any residual impurities and to stanĆ
dardize the water used to make soft drinks.
Carbon Dioxide
In the early days of soft drink manufacturing, carbon dioxide was made from sodium salts. This is why carbonated
beverages were called "sodas" or "soda water".
When you open a soft drink bottle or a can of pop you hear the "fizz" you see is the rapid escape of carbon dioxide
gas caused by the sudden release of pressure on the beverage.
Flavors
Fruit-flavored soft drinks such as orange and lemon-lime often contain natural fruit extracts. Other flavors such
as root beer and ginger ale contain flavorings made from herbs and spices.
Colors
Color effects our psychological impression of food. If you don't believe it, try eating a familiar food in the dark.
Caffeine
It has been part of cola and pepper-type beverages since they were first formulated more than 100 years ago and
has been enjoyed in coffee, tea and chocolate beverages for centuries.
Acidulants
Acidulates add a pleasant tartness to soft drinks. Two common food acidulates - phosphoric acid and citric acid.
Preservatives
Soft drinks do not normally spoil because of their acidity and carbonation. However, storage conditions and storĆ
age time can sometimes impact taste and flavor.
Potassium
Potassium exists naturally in drinking water and therefore, soft drinks.
Sodium
Soft drinks are classified by FDA as "low" or "very low" sodium foods.
SD 107
8
SWEETENERS
Non-Diet Soft Drinks
Most regular (non-diet) soft drinks are sweetened with either sucrose or high fructose corn syrup, (HFCS).
With either, the amount of sweetener in a soft drink ranges from 7 to 14%.
DIET SOFT DRINKS
While only two sweeteners, aspartame and saccharin, are approved for use in soft drinks today, innovations are
expected in the new future.
Aspartame
Aspartame was first approved for use in some foods in 1981, and for soft drinks in 1983.
Saccharin
Discovered more than 100 years ago, saccharin is the only non-caloric diet sweetener currently approved for soft
drink use in the U.S.
Saccharin is extremely sweet - about 300 times sweeter than sugar.
Alternative Sweeteners
Manufacturers can blend sweeteners to match beverage formulations and better appeal to all consumers.
"Sunette" is a new diet sweetener recently approved for certain food uses, but not yet for soft drinks.
Sucralose, a derivative of sucrose that is 600 times sweeter than sucrose, and alitame, a compound similar to asparĆ
tame that is remarkably 2,000 times sweeter than sucrose.
As an example, a very fine quality sparkling water was run in the Technical Service Laboratory of the NSDA to
see how it behaved during these handling steps. Using a special procedure, the gas content of this water was evaĆ
luated at all steps. Using clean, cooled glasses of ordinary size, here are the results obtained:
CARBONATION RETENTION TESTS
#1
#2
#3
#4
42°F
82°F
42°F
42°F
Fine
Fine
Fine
Particles
Original Carbonation
4.5
4.5
5.5
4.5
Very Carefully
4.0
3.1
4.1
3.0
Average
3.4
2.1
3.2
2.6
Poured Over Cracked Ice
2.3
1.7
---
2.1
CONDITIONS
From the results in column #1, it is obvious that with the best of conditions there is still considerable loss of gas
serving, particularly if the beverage is subject to high levels of agitation in the glass. Note that this product of very
high quality could be made inferior by careless serving (dispensing).
Another factor can be easily shown by the figures in column #2, namely, the effect of temperature on the behavior
of the product. Using a second sampling of the sparkling water, the same routine was carried out, differing only
in that the water was at room temperature of 82 degrees F. From this example, it is quite obvious that it is wise to
serve a "carbonated" beverage that has been chilled prior to dispensing, and that it is particularly undesirable to
try to cool the "carbonated" product by using cracked ice.
9
SD 107
The question arises as to what would happen if the carbonation of this product was raised, and therefore, some
of the same water was carbonated at 5.5 volumes, see column #3 on the table. With this carbonation factor, the prodĆ
uct was found to be very touchy, if not "wild", and threw off an excessive amount of gas during the dispensing
cycle. Even with a higher original (starting) carbonation level, the best that could be obtained when cooled in the
glass was a gas content (in the glass) of 4.1 volumes, which compared with the 4.0 volumes resulting in the first
experiment using the lower carbonation. But the interesting fact comes when you observe the results of the higher
carbonated water being poured in an average (after pouring) dropped to 3.2 volumes, which shows a definite loss
as compacted to the 3.4 volumes in the final glass of carbonated water using the lower carbonation. Boosting the
carbonation made the product, pouring out of the glass, less lively than before. The natural question is, why can't
more gas be put in a beverage beyond a reasonable amount, in an effort to obtain better life? The answer lies in the
"load" of gas which exerts a very definite strain or tension in the liquid as it is served.
In another test (Condition #4), a sparkling water which showed suspended matter, in the bottle, was tested in the
identical manner as our first example. (Condition #1). The sample had the same carbonation level as #1, 4.5 volĆ
umes, and the water was poured into the glass at a temperature of 42 degrees F° When the results are compared
(#1 vs #4) it is quite obvious that the particles suspended in Condition #4 had a definite destructive effect on the
carbonation.
These particles are generally spoken of a nuclei on which bubbles form, and experimentally with unusually clean
apparatuses, it has been possible to go to excessive carbonation loss without an tendency for bubbles to form, as
the pressures are released. It is, therefore, believed that in the majority of cases the particles where "the culprit"
in causing the gas to "unload", and that those particles showing negative charge are the most likely to cause this
phenomenon, for some particles without the necessary charge will not cause bubbles to form.
To observe on any given product, take a properly chilled (40 F or below) bottle and open "quietly" by taking the
crown off slowly (the bottle should also have stood "quietly" for at least 15 minutes prior to starting the test). Then,
with cross lighting, watch to see where the bubbles of gas form. Where the "carbonated" product (water) is exĆ
tremely clear and bright, and the bottle well washed, with clean inner surface, bubbles will form a very slow "bubĆ
bling". If, however, there are a number of active particles or nuclei present, bubbles will form rapidly in the body
of the liquid.
Particles may even be seen "dancing" around in the liquid, with a feather or stream of bubbles arising as they do.
If the bottle is dirty, the bubbles will form at an excessive rate on the glass surface. In general, the elimination of
such difficulties is through better clarification of the water used, or better cleaning of the inside of the bottle. To
show how particles affect a product, flick some ashes or dirt particles into a well carbonated beverage and observe
the rapid gas loss. The sharpened end of a lead pencil will give you the same effect.
WHAT IS A SATISFACTORY CARBONATED DRINK?
Probably one of the most important items in any discussion regarding the dispensing and servicing of a carbonated
beverage dispensing system is a clear understanding as to just what is a desirable carbonated drink.
One factor certainly is that the brix (syrup-water ratio) is proper for the flavor, as it was determined by the developĆ
er of the product. The second is that the flavor is carbonated at a level that the developer also determined to be
best for that particular flavor. Let's look at the desired end result.… that is, the drink that has been served along
with a sandwich. The sandwich is partly consumed, a sip is taken of the drink, once again some of the sandwich
is eaten and then another sip of the drink is taken until all of the sandwich is consumed and a small amount of the
"carbonated" beverage is left. Now comes the most critical moment for that drink. When the last sip is taken, it
should still have a good flavor.… cold and carbonated. If beverage quality is maintained from the first to the last
sip you are insured of repeat sales. It determines whether or not the consumer remembers it as a pleasant and desirĆ
able drink to the point of ordering it the next time and/or even returning to the same outlet at a later time, to purĆ
chase those same items.
SD 107
10
Certainly this all does not happen by accident. It is a combination of:
Quality Flavors - That Are Recognized and Desired.
Quality Dispensing Equipment - To Maintain A Cold-Carbonated Beverage At The Desired Consumption Level.
Knowledgeable Representation - To Consult And Direct The Operator To What Is Best For Their Needs… Proper
"Sizing" Of The Dispensing System.
Knowledgeable Installation Team - To Insure Proper Installation Of The System.
Knowledgeable Service Team - To Efficiently And Effectively Troubleshoot The Dispensing Station.
Knowledgeable Operators - To Understand The "Working" Of Their Dispensing System.
All of these elements are required in order to insure that both system and the "carbonated" beverage is focused
to the desired goal… customer satisfaction and repeat sales of your products.
WHAT IS SATISFACTORY CARBONATION?
We generally refer to the amount of carbon dioxide gas dissolved in the beverage as volumes, as determined by
temperature and pressure read from the standard charts or computer. The column simply means the relative bulk
gas dissolved in the liquid and, although it seems odd that several bulk volumes of gas will disappear into one
bulk volume of water, yet this is a chemical phenomenon known as gas solution. To bring about the gas solution,
pressure is needed, and when the pressure is released on the gas, out it comes again.
When the pressure of the carbon dioxide gas is only of the atmosphere in which we live, we find that the gas
dissolves in amounts determined by the temperature of the water. Gas will dissolve without pressure to 1.71 volĆ
umes of carbonation at the freezing temperature of water and to 0.56 volumes of carbonation at 100 degrees F.
To get greater amounts of carbon dioxide into solution. It is necessary to increase the pressure of the gas on the
water. This is indicated on a chart or computer by the increase in volumes and the gauge pressure beginning at zero
(which is atmospheric pressure) and proceeds on to 100 pounds per square inch. The important thing to notice is
that every time the gas pressure is increased by 14.7 pounds per square inch, the gas content increase on multiple
of the atmospheric pressure, for a given temperature. For example, we find that at 60 degrees F. one volume of
carbon dioxide will dissolve in on volume of product at atmospheric pressure (zero #/sp. in on gauge). Then as
the gauge pressure reaches 14.7, the amount of gas dissolved becomes 2.0 volumes, at 29.4 the amount of gas is
3.0 volumes, at 44.1 the amount of gas is 4.0 volumes, etc. This same multiple ratio of solubility holds true at norĆ
mally used temperatures.
In practice, the amount of gas wanted are such that pressure is needed to get the amounts of "load" of carbon dioxĆ
ide in the liquid and by such process the gas is placed in a "tension" in the liquid, and is held there by the pressure
placed on it. To a certain extent, this is the same placing pressure on a long, coiled spring and compacting it; as long
as the pressure is released, it uncoils regularly until all of this load tension is gone. So it is with carbonated liquids
- the gas content or "load" is held in by pressure creating a tension on the gas in the liquid so that when the pressure
is removed (as it is when a bottle or can is opened), the gas moves out of the liquid until it is back to the original
conditions before the pressure was applied.
The next important consideration is the effect that the varying degrees of carbonation will have on the finished
beverage, its appearance, taste, and general behavior..
Depending somewhat on the type of beverage, carbonations much above 3.5 volumes tend to throw off too much
carbon dioxide in the mouth and throat, causing choking or irritation. It is quite satisfactory, therefore, to say that
for the majority of products it is not necessary to have over 3.5 volumes of gas in the beverage at the time it is being
consumed, to give the most desirable pungency and taste sensation. However, since there is always some gas lost
when a bottle or can is opened or poured from, an additional gas content must be considered. Carbonation loss
when dispensing from a properly set pre-mix or post-mix system is minimal.
The amounts of carbon dioxide lost as a beverage is dispensed vary. The gas loss is negligible when the product
has been cooled and not unduly disturbed. However, when the beverage is poured into a glass mechanical agitaĆ
11
SD 107
tion occurs which more of less tends to "throw" the gas out of the liquid. As long as the gas loss (in pouring) does
not become so great that the resulting beverage has dropped below the reasonable (expected) taste range and beĆ
comes "flat", it is not wasted, for the bubbles formed furnish a direct eye appeal, i.e., foam. It is not uncommon
to find that from 0.5 to 3.0 or more volumes of gas have been lost just in the dispensing. The more agitation that
occurs from either having a spoon or cracked ice in the glass or pouring from a point higher than that at the lip
of the glass tends to increase the gas loss, and is often the cause of "flatness". It is important to note at this point
that the temperature of the beverage greatly influences the amount of gas loss produced by agitation; the tendency
being that the lower the temperature of the beverage, the more stable it is. It is far better to pour a cold beverage
over cracked ice that to try to pour warm beverage in the same manner and depending on the ice to do the cooling
- for the latter case a disturbance will take place in the carbonated beverage before it has time to be cooled (by the
ice), and extreme gas loss will occur. Once the beverage is placed in a glass it should have at least enough carbonĆ
ation to show some life during the period in which the beverage is being consumed, the carbonation being part
of it's appeal, and lastly it must still posses it's necessary pungency to the taste. If by chance it is mixed with other
liquids which are not carbonated, they will absorb some of the gas from the beverage and will thereby tend to dilute
and lower the general carbonation. In general it has been found that if the beverage is finally quiet in the glass after
the disturbance of dispensing with from 2.5 to 3.5 volumes of carbonation, it will not be lifeless.
A very logical question is often asked as to whether or not there is any way that the gas can "release" out of a carbonĆ
ated beverage other than through bubbles. The answer is that the gas can leave or "release" by a substantially invisĆ
ible process known as diffusion, in which the gas moves slowly through the open surface of the beverage and into
the surrounding atmosphere. Diffusion will cease as soon as the pressures have equalized.
It may be said that the indication of how fast the beverage is losing it's gas is in direct relationship to the speed of
bubble formation. Thus concluding that a condition of rapid bubble formation, in a carbonated beverage, may indiĆ
cate life at the particular moment, however, the product which will stay alive the longest… is one which may apĆ
pear almost dead and will bubble only when disturbed. Even though the bubbles forming at any one time appear
to have only a small volume, they rapidly amount to an appreciable amount of gas lose.*Reference: Technical SerĆ
vice Department - NSDA
A carbonated soft drink dispensed at approximately 42°F. will result in about 12% of it's carbonation
lost. Soft drinks are at the "peak" of their taste appeal when dispensed and served below 40°F. ServĆ
ing warm carbonated drinks over ice will contribute and accelerate the carbonation loss, as well as,
weaken (dilute) the finished drink to an undesirable level and brix.
Temperature of
Drink
(C)
Temperature of
Drink
(F)
Carbonation
Loss of
Carbonation
2°
36°
100%
0%
3°
38°
96%
4%
4°
40°
92%
8%
5°
42°
88%
12%
6.5°
44°
84%
16%
7.5°
46°
81%
19%
8.5°
48°
78%
22%
9.5°
50°
75%
25%
11°
52°
72%
28%
12°
54°
69%
31%
SD 107
12
A DISCUSSION OF CO2 BOOSTER PRESSURE AND ITS
VARYING EFFECTS ON A PRE-MIX SYSTEM
CO2 gas is one of the essential ingredients in any carbonated soft drink. In Pre-Mix, this CO2 gas is
mixed with the other essential ingredients in the proper proportions and placed in a sealed stainless
steel container at the bottling plant. The beverage so prepared is the ready to be consumed. Even
though the beverage in the Pre-Mix tank is completely prepared, there are two more important
things that must be done in order to make it ready for the consumer's lips:
D. This beverage which now has various amounts of CO2 gas absorbed in it and is under a
head pressure of CO2 must be brought into the atmosphere and placed into a glass or
cup without losing that recommended amount of gas that has been absorbed by it. This
is the function of the dispensing valve.
D. The second thing is that the product must be chilled properly from its temperature in the
tank to the range of from 33° to 40° in order to provide taste appeal. Cooling the beverĆ
age also assists the dispensing valve in doing its job properly, in as much as cold beverĆ
age will hold CO2 gas in solution much more easily than warm beverage.
In any Pre-Mix system, we must have a source of constantly regulated operating pressure to pump
the beverage through the system as well as to maintain the proper level of gas absorbed in the beverĆ
age by replacing the space in the Pre-Mix tank vacated by the beverage as it moves from the Pre-Mix
tank into the consumers glass. Because there is a set physical relationship between the pounds of gas
pressure dissolved in the beverage, the temperature of the beverage, and the volumes of carbonation,
this operating pressure must be properly set at a pressure that will not force an undue amount of exĆ
cess gas into the beverage, thus raising the level of volumes. At the same time, operating pressure
must be set so that the beverage will not lose any of its gas charge as a result of certain pressure
losses inherent in the average Pre-Mix system.
It should be stated here than the average Pre-Mix tank, when full of beverage has approximately
four per cent (4%) of its volumetric capacity as expansion space or head space containing CO2 gas.
EQUILIBRIUM PRESSURE
A product tank that has counter or head pressure of equilibrium is one that has pressure just suffiĆ
cient to keep the recommended volume of CO2 gas absorbed in the product at a particular product
temperature. This equilibrium pressure is not a constant. It varies with the change in the product
temperature. As the product temperature increases, equilibrium pressure also increases. This is
caused by the fact that a container of water without any head pressure will absorb 1.71 volumes of
CO2 gas at 32°F. and only .56 volumes of CO2 gas at 100°F. If the pressure is not increased as the
product temperature rises, the product will lose .017 volumes of carbonation per degree of temperaĆ
ture rise.
13
SD 107
OPERATING PRESSURE
Operating pressure is equilibrium pressure plus enough pressure to overcome pressure loss or resisĆ
tance caused by the peculiarities of any specific system. Some of the peculiarities encountered that
offer a system resistance are (a) Manifolding together of more than one tank of product in the system.
(b) Operating pressure may have to pump product through lines for a considerable distance. (c) OpĆ
erating pressure may have to lift the product to first floor dispensing station from basement tank
storage location.
For these reasons, the correct operating pressure for any specific system must be determined accordĆ
ing to the peculiarities of the equipment installation.
To start with, experience has indicated that for the simplest of installations where the product lines
are short, not more than two or three tanks of product are connected in a series at one time, and the
tanks are on the same floor as the dispensing apparatus, setting the operating pressure at five
pounds (5#) more than equilibrium pressure is usually a good rule; therefore, in the case of the above
system, if the product is carbonated at 3.6 volumes and the product temperature is 70F., forty-eight
pounds (48#) is equilibrium pressure and fifty-three pounds (53#) would be operating pressure.
It is suggested that five pounds (5#) additional pressure be used as a starting point to which should
be added amounts of pressure to compensate for more rugged conditions than those in the above exĆ
ample. For instance, if the tanks are located on the floor below the dispensing station, one pound (1#)
of pressure should be added to our standard amount of five pounds (5#) for every (2) two feet of verĆ
tical distance between the top of the Pre- Mix tank and the dispensing valves on the floor above.
If, for example, this distance were to be ten feet (10') the resulting five pounds (5#) additional presĆ
sure should be added to our standard five, bringing the total to ten pounds (10#) of additional presĆ
sure to be added to equilibrium pressure in order to obtain the operating pressure for our CO2
regulator.
In this same example, if the product lines between the tanks and the cooling unit are quiet long,
approximately one pound (1#) of additional pressure should be added for every ten feet (10') of
product line over a basic length of ten feet (10'), which is compensated for in the original standard
addition of five pounds (5#); therefore, if the product lines are thirty feet (30') long, two additional
pounds (2#) should be added to the ten pounds (10#) already arrived at for this example.
If, in addition, the above installation required five tanks in one series rather than the average of three
or less, one pound (1#) should be added to the previous result of twelve (12#) for each additional
tank over three. In this example, if two pounds (2#) were added to the original twelve pounds (12#),
then the proper operating pressure for this system would be fourteen pounds (14#) above equilibriĆ
um pressure.
In determining the equilibrium pressure for a product in an installation, the highest temperature enĆ
countered by the product between the tank storage area and the cooling source must be considered.
It should be remembered that the above rules are not absolute, but have evolved, for the most part,
from experience. While these rules will generally hold true, they should be considered as merely a
starting point for further experience and common sense in dealing with the many abnormal condiĆ
tions often found in the customer's place of business.
In as much as no two equipment installations are exactly alike, we must have a thorough knowledge
of the fundamentals in order to remain imaginative and versatile in our approach toward solving
Pre-Mix problems.
SD 107
14
PRE-MIX SYSTEM EXAMPLES
Volumes of Carbonation
Volumes of Carbonation
Ambient Temperature
(Product Number 1)
(Product Number 2)
° F.
50 ft
1
1
1
2
2
2
Product
Number 1
Number 2
Equilibrium (Base) Pressure:
Simple System "Add-on" Pressure:
+
System "Push" Pressure:
+
System "Set" Pressure:
=
15
5#
5#
SD 107
PRE-MIX SYSTEM EXAMPLES
Volumes of Carbonation
Volumes of Carbonation
Ambient Temperature
(Product Number 1)
(Product Number 2)
° F.
50 ft
8 ft
1
1
1
2
2
2
Product
Number 1
Number 2
Equilibrium (Base) Pressure:
SD 107
Simple System "Add-on" Pressure:
+
System "Push" Pressure:
+
System "Set" Pressure:
=
16
5#
5#
PRE-MIX SYSTEM EXAMPLES
Volumes of Carbonation
Volumes of Carbonation
Ambient Temperature
(Product Number 1)
(Product Number 2)
° F.
30 ft
8 ft
10 ft
16 ft
1
1
1
2
2
2
Product
Number 1
Number 2
Equilibrium (Base) Pressure:
Simple System "Add-on" Pressure:
+
System "Push" Pressure:
+
System "Set" Pressure:
=
17
5#
5#
SD 107
LESS THAN EQUILIBRIUM
Attempting to dispense product at less then equilibrium is probably the greatest cause of foaming
complaints and flat product. Foaming generally occurs when operating pressure is slightly lower
than it should be or when the cooling unit is not doing an adequate job and the product is being disĆ
pensed in most cases above 40°F. Spitting at the dispensing valve is usually caused by operating
pressure being considerably lower than it should be. In the case of spitting, gas is leaving the product
rapidly in the form of large bubbles not only during dispensing, but also while the system is at rest.
These large bubbles will flow to the highest points in the product line or cooling unit and form gas
pockets. Spitting occurs when these gas pockets are forced through the lines and arrive at the disĆ
pensing valve.
OVER EQUILIBRIUM PRESSURE
Pressure in excess of equilibrium can in a period of time change the volume of CO2 gas held by the
product. As mentioned under "equilibrium pressure," temperature of the product has a great effect
upon the acceptance or rejection of CO2 gas by the product. As and example, if the product were
stored in a cool area and the product temperature is 45°F and equilibrium pressure is exceeded by ten
pounds, then the product CO2 volumes would be increased by .8 in approximately 16 hours if this is
a 3.6 volume product to begin with. If the product is a 4.0 volume product, then it increases .9 in
approximately 16 hours. According to the temperature rule, if the product temperature were lower
than 45°F and the over-pressure greater than ten pounds, the increase in the product carbonation
would be greater in a shorter period of time. Since 70°F product carbonated at 3.6 volumes will pick
up only .53 volumes of gas in approximately (60) hours and 4.0 volume product in the above examĆ
ple picks up only .55 volumes in sixty (60) hours, it is, therefore, a good practice especially when subĆ
stantial over-pressures are required to place the product tanks in as warm an area as possible. Warm
product will gain less volumes and require a longer period of time for absorption than cold product,
given the same amount of over pressure.
CHANGING PRODUCT VOLUMES OF CO2 GAS
If the product should be found "flat" the volumes of CO2 gas can be increased to the recommended
volumes by finding equilibrium pressure for the temperature of the product. Set this pressure on the
CO2 regulator, attach gas line to the product tank, and shake the tank vigorously until CO2 gas is not
longer heard entering the tank. The lower the product temperature, the less shaking will be required
to bring product volumes of CO2 to recommended point.
If Product should be found "over-carbonated", then excess volumes can be released by relieving the
head or counter-pressure in the product tank. After this is done, shake the tank vigorously; this
causes product to give off CO2 gas to replace pressure in head space.
If the product is only slightly over-carbonated, then usually one such operation is all that is required.
Be sure to test, and if required, repeat operation of relieving counter-pressure and releasing CO2 gas
from product until recommended volumes are obtained.
If a full tank has the head pressure released and then is shaken, the gas released to replace the head
pressure will reduce the product carbonation by approximately .2 of a volume if the product was 4.0
volume.
If, by chance, product CO2 volumes should be reduced too far, they can be raised at outlined in the
previous paragraph.
SD 107
18
PROCEDURE FOR TESTING VOLUMES OF CO2
GAS IN CARBONATED BEVERAGES WITH
CORNELIUS TESTER
1. I. Test of Tank Pressure for Full Tank Only!
A. Agitate product tank to stabilize gas held in product. This can be done by vigorously shakĆ
ing tank or rolling it on floor until pressure readings are stabilized).
B.
Press gauge on inlet or gas side and note maximum reading.
2. Set CO2 Regulator to Pressure Reading Secured Above and Connect Line to Tank.
3. Press Product Sampler on Liquid or Outlet Side of Tank.
A. Draw approximately 2 ounces of product in glass or paper cup (if glass is used, its temperaĆ
ture must be stabilized with that of the product in the tank).
B.
Place thermometer in product and stir to adjust thermometer to product temperature; pour
out product.
C.
Draw approximately 3 ounces of product; stir with thermometer. Note temperature - This is
product temperature.
4. Using a Cornelius Pre-Mix Computer or Bottling Room Chart.
A. Using a Cornelius Computer, locate final pressure reading on "C" scale over final temperaĆ
ture reading on "D" scale, read volumes of CO2 on "A" scale above large arrow on "B" scale.
B.
Using Bottling Room Chart, look across chart to box where final pressure and product temĆ
perature lines intersect - this is volumes of CO2 product.
SANITIZING PROCEDURES FOR CORNELIUS
PRE-MIX EQUIPMENT
OBJECTIVE: The purpose of this procedure is to ensure the quality of soft drinks
dispensed through pre-mix equipment by maintaining the proper sanitation of a system
(unit) on a regularly scheduled basis.
IMPORTANT: Only qualified personnel should perform sanitizing procedure.
The product systems should be sanitized every 90-180 days. Use Chlor-Tergent (Oakite Products,
Inc.) or equivalent sanitizer.
1. Disconnect refrigeration system electrical source or remove ice from cold plate, if ice refrigerated.
2. Remove quick disconnects from product tanks. Rinse quick disconnects in plain warm water.
3. Using a clean empty product tank, prepare a full tank of sanitizing solution by filling the tank
with 70°F to 100°F (max) water and adding 0.68 ounce of Chlor-Tergent per gallon. This proĆ
vides 200 PPM of chlorine. Make certain sanitizing solution is fully dissolved, i.e., stir. If using
an equivalent sanitizer be sure to follow package directions to obtain 200 PPM of chlorine.
19
SD 107
4. Connect the tank of sanitizing solution (combination detergent and bactericide) to a CO2 cylinder
with the regulator set at 50 PSI. Then connect a product line to the tank.
5. Place a waste container under dispensing valve. Open dispensing valve to permit sanitizing
solution to purge product out of system, cooling coil, and dispensing valve. Continue to draw
from valve until only sanitizing solution is dispensed.
NOTE: It requires approximately 1/8 of a tank of solution to flush and fill 2 product lines and
cooling coils with sanitizing solution when each product line is approximately 50 feet long.
6. Repeat steps 4) and 5) preceding to purge product from, and install sanitizing solution in the reĆ
maining product lines.
7. Disconnect sanitizing tank and allow sanitizing solution to remain in syrup systems for not less
than 10 or more than 15 minutes (max) contact time.
WARNING: To avoid possible personal injury or property damage, do not attempt to
remove syrup tank cover until CO2 pressure has been released from tank.
NOTE: While allowing sanitizing solution to remain in system(s) general cleaning and inspection
can be performed.
Remove drip tray assembly and/or cup rest (or bar gun hose holder). Wash with mild soap solution,
then rinse thoroughly with warm potable water.
Wash out cavity that drip tray/cup rest sits in (if applicable), with mild soap solution, then thoroughĆ
ly rinse with warm (100_F) water, also flushing drain hose assembly. Reinstall assembly and check
for leaks.
Clean all external surfaces of unit with sponge and mild soap solution. Rinse out sponge with clear/
clean water, then wring excess water out of sponge and wipe external surfaces of unit. Wipe unit dry
with a clean soft (lint free) cloth or paper towel. DO NOT USE ABRASIVE TYPE CLEANERS.
On electric units, clean condenser with condenser brush, removing grease and dirt build-up. Check
water bath level, refilling as necessary to top of stainless steel coil pack with clean potable water. USE
LOW-MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS.
If the refrigeration is a cold-plate type unit, scrub the exposed cold plate surfaces with a stiff brush
and cleansing powder. Rinse thoroughly. Check ice bin/hopper drain hose for proper drainage.
Check all connections for leaks.
Replace any missing flavor decals.
Clean and make necessary repairs to all CO2 regulators, using appropriate (primary and/or secondĆ
ary) repair kit(s). Replace all broken or malfunctioning regulator gauges. NOTE: Any regulator
gauge that does not "zero" when not under pressure is defective.
8. Connect a tank containing clean (100°F max) rinse water to first set of product lines.
9. Place waste container under dispensing valve. Open dispensing valve to permit rinse water to
purge sanitizing solution out of system and through dispensing valve. Continue to draw from
valve until only clear/clean rinse water is dispensing.
CAUTION: Flush sanitizing solution from syrup systems as instructed. Residual
solution left in systems could create a health hazard.
SD 107
20
10. Repeat step 9) to purge sanitizing solution out of remaining systems and dispensing valves until
only rinse water is dispensed.
11. Disconnect and replace all jumper line assemblies with assemblies that were sanitized at the
plant and sealed in disposable plastic bags.
12. Disconnect and replace gas line assemblies with assemblies that were sanitized at the plant and
sealed in disposable plastic bags. If gas line shows evidence of product contamination, inspect
the check valves at manifold.
13. Remove dispensing valve(s) from system.
14. Wash compensator in sanitizer. Rinse in clear water and replace. Inspect for compensator wear
or damage and replace accordingly. Re-install compensator.
15. Install dispensing valve body assembly that has been sanitized at the plant and sealed in a disĆ
posable bag. Visually inspect for cracks and proper fit of o-rings.
NOTE: An alternate to the preferred sanitizing procedure outlined above would be to remove disĆ
pensing valves. Then make necessary connections to circulate sanitizing solution through the
product systems, using adapter/manifold connections. While systems are being sanitized, the disĆ
pensing valves may then be fully disassembled and cleaned before re-installing onto unit.
KNOB
KNOB AND LEVER BONNET
FRICTION WASHER
BALL WASHER
LEVER
COMPENSATOR
BODY
INNER SLEEVE
SHAFT AND SEAT ASS’Y
SPRING
O-RING
OUTER SLEEVE
PHILLIPS HEAD SCREW
O-RING
COMPENSATOR ADJUSTING SCREW
MANUAL DISPENSING VALVE PARTS IDENTIFICATION
16. Inspect all product lines with a flashlight. If line(s) show evidence of yeast/mold, replace them.
17. Reconnect refrigeration or re-ice the cold plate.
18. Check CO2 pressures according to volumes of carbonation, per appropriate product and system
application. Using the Cornelius pre-mix computer, recalculate proper CO2 regulator pressure
setting(s) per system application and reset CO2 regulator pressures, accordingly.
19. Reconnect the predetermined CO2 (gas) line onto appropriate product tank. Check quick disconĆ
nect (gas-in) for proper o-ring seal.
21
SD 107
20. Reconnect the product line onto appropriate product tank. Check quick disconnect (product-out)
for proper o-ring seal.
21. Place waste container under dispensing valve. Open dispensing valve to permit product to
purge rinse water out of system and dispensing valve. Continue to draw from valve until only
product is dispensed.
22. Repeat step 21) to purge rinse water out of remaining lines and dispensing valves until product
is dispensed.
NOTE: Make certain all rinse water and air bubbles have been removed from system. Product
should flow clear without foam.
23. Wipe dispensing station clean with paper towel.
24. Adjust the flow rate of the dispensing valves.
25. Bleed CO2 pressure from the special tanks containing the sanitizing solution and rinse water.
26. Thoroughly rinse out special tank that was used for sanitizing solution to remove all solution
residue from inside tank.
27. Inspect entire system for leaks.
28. Record Service and/or complete inspection form.
29. Educate customer before leaving site.
Cold Plate Systems - Tamp ice to prevent "bridging".
Electric Units - Keep condenser clear of obstruction.
Bar Gun Systems - Soak in soda water or warm water overnight..
SANITIZING SPECIAL EVENT EQUIPMENT
Since often times special event equipment is stored until needed, each unit should be sanitized as
prescribed above. All dispensing equipment should be sanitized prior to being placed in storage.
Procedure:
1. Follow sanitizing procedures as described in steps 1-16.
2. Flush all water from the system with CO2 pressure and relieve.
3. Cover each dispensing valve with a clean disposable plastic bag and seal with wire or tape.
4. Place product line ends in clean disposable plastic bag and seal with wire or tape.
5. Tag and record date of service.
SANITIZING JUMPERS AND GAS LINE
ASSEMBLIES (IN-PLANT PROCEDURE)
The practice of in-plant sanitizing and preparation of jumper and gas line assemblies can be benefiĆ
cial and save time at the retail outlet should a reserve of these assemblies be maintained at your serĆ
vice department.
NOTE: Reference step 11) and step 12) of system sanitizing procedure.
SD 107
22
Procedure:
1. Submerge line assemblies in warm (90_F) water and soak for 10-15 minutes to clean exterior.
Scrub with stiff brush.
2. Place the line assemblies in clean/clear rinse water.
3. Using special tank containing properly prepared detergent and bactericide (cleaner/sanitizing)
solution (step 3) and force solution through line/quick disconnect assembly (step 4).
NOTE: Temporary connection of a product (out) quick disconnect will be required on loose-end
fitting set of gas line assembly being sanitized.
4. Disconnect line assembly being sanitized from special tank, and allow solution to remain in line
assembly for not less than 10 or no more than 15 minutes (max) contact time.
5. Connect tank containing clean warm (100°F max) water to line assembly and force rinse water
through line/quick disconnect assembly.
6. Connect line assembly to CO2 pressure source (50 psi) and force rinse water out of line assembly.
7. Wipe dry the line/quick disconnect assembly and store in clean disposable plastic bag, for future
use. Wire tie or tape closed.
EQUIPMENT REQUIRED FOR SANITIZING
Three (3) Stainless Steel Product Tanks:
1 - Filled with properly prepared detergent/bactericide (cleaner/sanitizing) solution.
1 - Filled with clear/clean rinse water (100°F max).
1 - For collecting used sanitizing solution and rinse water.
S
CO2 Supply (set at 50 psi)
S
Supply of paper towels
S
Supply of sanitized gas line assemblies
S
Supply of sanitized jumper line assemblies
S
Supply of sanitized dispensing valves
S
3 - 5' rubber/plastic water hose (to fill tanks)
S
Sanitizer/cleaner (Chlor-Tergent/Oakite Products, Inc.)
S
Stiff fiber scrub brush
S
Cleansing powder
S
Mild soap/detergent (liquid)
S
Ice scoop
S
CO2 regulator wrench (P/N 134410)
S
Valve spanner wrench (P/N 151689)
S
Flashlight
S
Open-end wrenches (selection)
S
Oetiker clamping tool (P/N 311938) and/or Ferrule crimping tool set (P/N
274261300)
S
Assortment of Oetiker clamps and/or Ferrules
23
SD 107
S
Assortment of o-rings, gaskets and CO2 washers
S
CO2 regulator repair kit (both primary and secondary kits)
S Selection of CO2 regulator gauges (hi-pressure, 160lb. and 100lb.)
NOTE: Hi-pressure gauge replacement may require either right-hand or left-hand threads.
SD 107
24
TROUBLESHOOTING
BASIC ITEMS TO CHECK ON CORNELIUS PRE–MIX DISPENSING EQUIPMENT IF IT IS
MALFUNCTIONING
1. Product does not come out dispensing valve when it is opened.
A. Check product tank or tanks that contain particular flavor. Make sure tanks are not empty. If
more than one tank in series, and all are empty replace these tanks. If even one is partially
full, this is not cause of problem.
B.
Check CO2 cylinder. If high pressure gauge (0-2000) needle shows reading, CO2 is not cause
of problem. If gauge shows 0, cylinder needs to be replaced.
C.
Check all quick disconnects. Make sure all quick disconnects are seated on product tank fitĆ
tings; one being loose or note seated on product tank will stop product from dispensing.
D. If these three items are all right, call Service Department.
2. Product has excessive foam in glass or cup.
A. Check temperature of product. If cooling source is not operating properly or is out of ice,
this will be a result.
B.
If CO2 high pressure gauge (0-2000) shows reading of over 600 pounds, CO2 cylinder is
okay. If reading is below 60 pounds, this is cause. Replace cylinder. If reading is below 400
pounds, replace cylinder as it will soon be empty.
C.
If dispensing valve is flowing too fast this can cause foam. Reduce flow slightly by turning
in adjustment screw on right side of valve body. Caution: Do not turn it over 3/4 of a full
turn, and do not force screw.
3. To change product tanks when supply is completely gone.
A. Remove empty product tanks by removing both the inlet and the outlet quick disconnects.
B.
Place full tank in place of empty tank. Replace quick disconnects. Be sure to put inlet on inĆ
let fitting and outlet on outlet fitting. Do not force quick disconnects. If they do not go on
reasonably easy, try other fitting.
25
SD 107
4. To exchange product tanks in system of two or more tanks in series.
A. If system has a partial tank left in stock, place full tank or tanks in the system nearest the
cooling unit as the tank nearest the CO2 cylinder empties first.
B.
If one or more full tanks and a partial are left and another tank or tanks are replaced, put
new full tank nearest cooling unit. If a partial tank should be installed in system in any place
but next to CO2 cylinder, it will cause foaming.
5. In case of excess product leak at dispensing valve or cooling unit, remove quick disconnects
from this flavor product tank or tanks nearest the cooling unit.
SD 107
26
COLD PLATE VS MECHANICAL REFRIGERATED SYSTEMS
The following is a comparison of a cold plate system vs. a mechanically refrigerated fountain beverĆ
age system.
Cold plate systems are functionally simple; an aluminum block with stainless steel coils embedded
(cast) into the aluminum. The embedded stainless steel coils are the vehicle used to transport the
product (syrup and water or pre-mix product) and the aluminum material is used to transfer (draw)
the heat from the product contained. A cold plate is always positioned toward the bottom of an ice
bin. There are typically two types of cold plate-to-bin systems, i.e., sealed-in and unsealed (lose). To
ensure proper water "run-off" the top surface of a cold plate must be slanted, Most "loose" cold
plates are manufactured with two legs shorter, i.e., tilted. In a "sealed-in" application the top surface
of the cold plate is normally slanted to a center or corner drain hole. Both applications accommodate
drainage, of the water (melted ice), from the cold plate surface and interior of the bin. It is extremely
important the ice remain in contact with a cold plate's (top) surface, at all ties, to achieve maximum
cooling, i.e., heat transfer of the product contained instead the embedded coils. Obviously, this type
of system requires ice to be available during dispensing periods.
Mechanical refrigerated systems are somewhat more sophisticated then that of a simple cold plate.
A mechanically refrigerated system literally builds it's own "ice bank" within the confines of a "waĆ
ter bath" and it is totally independent of other equipment to dispensed a properly chilled beverage.
The mechanical part of the system is related to the direct needs of an account, because the stainless
steel coils, containing the product, like that of a cold plate, are submerged in a "water bath" (containĆ
ing the "ice bank") and transfer of heat is somewhat faster and more consistent. A typical mechanical
refrigerated system contains; the product coils which transfer the products and aid in the heat transĆ
fer, evaporator coils which keeps the "water bath" in motion around the product coils. The agitation,
of the "water bath" is probably the most significant part of a mechanically refrigerated system. ReĆ
member… all cold plate systems require ice agitation,where as, in a mechanically refrigerated system
the agitation of the cooling source is incorporated. Ice agitation, on a cold plate system is usually saĆ
tisfied when ice, from the bin, is scooped into a large sup. In the case of ice/drink (combo) dispensĆ
ers. the ice agitation is normally satisfied via an incorporated auger assembly.
Typically, an operator purchases an ice machine for the sole purpose of supplying ice, in the cup,
along with a beverage. Seldom does the operator consider the amount of ice that will be required and
utilized in the cooling of a cold plate system. General rule of thumb, regarding cold plate ice conĆ
sumption (ice required for cooling) is as follows:
Cold Plate Systems - Require approximately 10# Ice/1100 oz. Finished Product
Typically, between 25-30% of ice consumption is used for product cooling in an ice-cooled (cold
plate) system. 70-75% of ice is used in the drinks.
In the functional application of a cold plate system, the bin is filled with ice (wet) and ice is in contact
with the cold plate. A dispensing tower or bar gun is mounted on/or close to the ice bin and connecĆ
tions are made at the cold plate. These line connections are sometimes as much as two feet (24")
long… from the cold plate to the dispensing valve. This is the area that is most prone to creating a
problem due to warm-up of the product(s) during non-peak dispensing periods, i.e., non-refrigerĆ
ated lines. When drawing drinks on a continuous basis, "peak period drinks" will be within the qualĆ
ity temperature standards of 40°F, or less. However, drinks that are drawn four minutes apart (or
longer), "casual drink periods", will exceed the quality drink temperature standards. It has been
further noted, that in dispensing a post-mix drink at fast flow rates (3 oz./second), even hard ice has
a tendency to "bridge", i.e., ice will loose contact at the cold plate surface. When bridging occurs the
pocket between the ice and the cold plate surface begins to retain heat rather the remove heat, Similar
conditions will result if water (melted ice) is not properly drained off the cold plate surface. Drink
temperatures, under these conditions, have been know to rise +20°F.
One of the major benefits of a mechanically refrigerated system is it's design to maintain a consisĆ
tent quality drink temperature during peak and non-peak (casual draw) dispensing periods, proĆ
27
SD 107
viding the placement has been properly "sized". This consistent drink temperature is accomplished
by keeping the product coils in close-contact with the cooling source.
In countertop applications the dispensing valve panel is located directly in front of the "water bath"
which house the "ice bank". These type countertop systems range from a small to large and are typiĆ
cally used in low - medium volume operations where the "casual drink temperatures" will be of
concern. Counter-top Ice/Drink Combo Units have recently become quite popular to the self-serve
marketplace. Convenience stores, cafeterias, refill stations and alike have taken a liking to the conveĆ
niences that a "combo" unit offers. There are several "types" of ice/drink dispensers in the market
today, ranging from ice-cooled (cold plate) application to mechanically refrigerated cooling systems.
All units are self-contained and feature drink and ice dispensing in one convenient package. In cerĆ
tain cases, an operation will prefer to separate the drink dispensing from the ice dispensing station,
due to traffic volume and back-up during those "peak" periods. Again, the cold plate application is
the simplest… and less prone to breakdown. Further advances into improvement of the product (disĆ
penser) have resulted in significant improvements regarding maintaining the drinks temperature
during non-peak periods. Slanting the cold plate "upwards" and positioning it and the carb water
manifold closer to the valve panel have demonstrated significant improvement during the "casual
drink period". In efforts to accommodate ease of replenishing the ice storage bin, with ice, several
models are now made available that actually incorporate an ice making devise or allow for "topmounting" of an ice making machine. The latest developments and designs will allow for "manual"
replenishing of the ice in the event the ice making devise fails. This has been accomplished by incorĆ
porating top-front "access panels", which position directly in front of a top-mounted ice machine,
while others have designed "slide kits" to allow for manual filling during "ice-out" situation.
In conclusion, ice-cooled cold plate systems are the simplest of design and maintenance, however,
drink temperatures during "casual drink periods" can have a negative impact on your drink quality.
SD 107
28
STANDARD PRE-MIX DISPENSING VALVE
1. Operation.
A. Sealing Points.
B.
a.
Inlet to shank - O-ring used on yoke and standard type - gasket on angle shank.
b.
Body to shank - O-ring at shoulder of shank.
c.
Adjustment screw - O-ring.
d.
Valve shaft - molded seat.
Flow Control.
a.
Compensator
b.
Reduces operating pressure to atmospheric pressure
c.
Determines rate of flow (2 ounces per second)
d.
Adjustment screw pushes compensator into shank to control clearance for above adjustĆ
ments.
e.
Test all compensators by installing backwards in shank 3/4" and rotate, if it rotates freeĆ
ly it will not jam when in normal use.
2. Styles - All Self-Closing
A. Two different length sleeves
B.
a.
1-1/2" angle and yoke style
b.
2-5/8" standard style
Push back lever kit available
a.
With or without I.D. knob
3. Sanitizing.
A. Completely disassemble
B.
a.
Scrub shaft bore with brush
b.
Clean 2 vent holes
c.
Rinse and dry before storing in plastic bags
Installing and removing from coupling nut use spanner wrench not water pump pliers or
pipe wrench. Do not over torque, spanner wrench gives proper leverage.
29
SD 107
BAR VALVE - FIVE PRODUCT
1. Operation.
A. Operating pressure of product is reduced to dispensing pressure by:
a.
The length and size of tubing from the cold plate to the valve. (If harness is made longer
flow may be too slow).
b.
The design of the valve shaft and connector.
2. Seals in valve.
A. O-ring on connector in rear of main body
B.
Valve shaft seal
C.
Valve shaft gasket - push button side.
3. Tubing held on by ferrules or clamps like other tubing, but uses spacer because of small
size.
A. Tubing - .114 I.D. vinyl should be heated with water before installing on connector.
4. To reduce possibility of kinking of tubing - poly tubing installed over tubing and ferĆ
rules plus green nylon cover.
5. Disassembly for sanitizing or repair.
A. Remove 3 screws from rear housing (slide housing and jacket back by pulling on far end of
jacket).
B.
Remove 3 screws retaining connectors in main body
C.
Carefully pull out connectors one at a time (note 3 short and 2 long - long at bottom).
D. Snap off product identifying collars.
E.
Remove set screw from push buttons (completely).
F.
Remove push button and return spring (note gasket in bottom of push button hole).
G. Remove valve shaft.
H. Reverse procedure for assembly.
I.
On replacing retainer screws for connectors do not over tighten.
IMPORTANT NOTE: Push button set screw must seat in groove on valve shaft when it is tightened
or it will not let valve shaft come out far enough to seat. Spring is installed with the larger end in toĆ
wards gasket. Before the rear housing is installed on the head, the jacket must be pulled so as to seat
the upper jacket ferrule firmly into housing. If this is not done, jacket can slide up in housing and
cause small tubing to be pinched, this causes restrictions, dispensing problems and may cause leaks.
SD 107
30
6. Installation
A. Ferrule on connector end must be held by a plier while swivel nut is being tightened to be
sure small tubing is not twisted causing restriction in line, it will occur under jacket where it
can not be seen.
B.
Do not overĆtighten swivel nut so that nylon washer causes restriction.
C.
Strain relief provided with valve must be used as it places all strain on jacket when valve is
used instead of small lines.
D. When plain water is dispensed and the supply pressure is 50 psig or more, a water pressure
reducing regulator must be used to eliminate water hammer. Water hammering causes broĆ
ken lines.
31
SD 107
Pre–Mix Parameters
List the 6 elements that make-up a quality fountain drink.
1. Water (Quality)___________________________________________________________________
2. ________________________________________________________________________________
3. ________________________________________________________________________________
4. ________________________________________________________________________________
5. ________________________________________________________________________________
6. ________________________________________________________________________________
2. List the 2 types of fountain systems.
1. ________________________________________________________________________________
2. ________________________________________________________________________________
3. Daily "Peak Dispensing Periods", at the retail operation, is critical in the selection of "type & size" of disĆ
pensing equipment to be recommended.
j True
j False
j Does not apply
4. When a CO2 cylinder is empty you should store it with the CO2 valve open?
j True
j False
5. When readjusting CO2 pressure on a CO2 regulator you should back
the pressure down 15 psig below the desired setting, then proceed.
j True
j False
6. Mechanical refrigeration (compressor) type systems are superior to Ice-Cooled (cold plate) application durĆ
ing "Non-peak" dispensing periods.
j True
j False
7. An Ice/Drink Dispenser (Combo) is designed to fit in every market application.
j True
j False
8. Define Volumes of Carbonation:
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
SD 107
32
9. What are the two "tools" used in solving a pre-mix problem?
j Temperature and Quality of Drink
j Temperature and Pressure
j Pressure and Dispensing Equipment
j Spanner Wrench and Thermometer
10. Pre-Mix Dispensing Valves are designed to dispense at a flow rate of:
j 1 oz./second
j 1-1/2 oz./second
j 2 oz./second
11. Pre-Mix product quality is that of a Bottle or Can.
j Less Than
j Greater Than
j Same As
12. If you experience foaming of product at the valve, on a pre-mix system, your product is?
j Over Pressurized
j Under Pressurized
j Over Carbonated
j Under Carbonated
j Too Cold
13. If you experience spitting of product at the valve, on a pre-mix system, your product is?
j Over Pressurized
j Under Pressurized
j Over Carbonated
j Under Carbonated
14. What type of cup is not recommended for fountain products?
j Glass
j Plastic
j Wax
j Styrofoam
15. How "cold" is ice?
A. 31_F
B. 0_F
C. As cold as the area it's stored in.
D. As cold as the ice maker makes it.
E. C & D (above) are correct.
33
SD 107
16. What statement best represents the best type of ice to be used when dispensing a fountain drink?
A. As cold as possible (freeze type).
B. Ice that is warm enough to have rough edges melted off (wet).
C. "Quality Ice".
D. B & C (above) are correct.
17. All pre-mix systems require a pressure (regulator) setting of 60 PSI.
j True
j False
18. "Ideal"carbonation volumes in a fountain product range from:
j 2.5 - 3.5 Volumes
j 3.2 - 3.8 Volumes
j 3.8 - 4.4 Volumes
j 4.2 - 4.8 Volumes
19. Why should a fountain drink be dispensed below 40_F?
j Over 40_F will result in "carbonation breakout" (foaming).
j Under 40_F will result in "carbonation breakout" (foaming).
j Stratification will occur if product is not dispensed below 40_F.
20. Brix is the terminology used to define:
j Volumes of Carbonation
j Ratio of Syrup & Water
j Amount of Solids (Sugar Content)
j None of the above
21. When checking volume of carbonation (of pre-mix product) at a product tank you should check a
tank that has been already hooked-up to the system?
j True
j False
SD 107
34
IMI CORNELIUS INC.
Toll Free Assistance
1-800-238-3600
Press 2 for Headquarters
Press 5 for Service
35
SD 107
CO2 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
CO2 Regulator
Primary and Secondary Types . . . . . . . . . . . . . . . . . . . . . . . . . .
2
PRIMARY vs. SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Identification of springs in primary or secondary regulators .
6
Repairing CO2 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
WHAT'S IN SOFT DRINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SWEETENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Diet Soft Drinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
CAUTION - do not make operating pressure connections to high side. . . . . .
CARBONATION RETENTION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
9
A DISCUSSION OF CO2 BOOSTER PRESSURE AND ITS VARYING EFFECTS ON A PRE-MIX
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
EQUILIBRIUM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
OPERATING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
LESS THAN EQUILIBRIUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
OVER EQUILIBRIUM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
CHANGING PRODUCT VOLUMES OF CO2 GAS . . . . . . . . . . . . . .
18
PROCEDURE FOR TESTING VOLUMES OF CO2 GAS IN CARBONATED BEVERAGES WITH
CORNELIUS TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
SANITIZING PROCEDURES FOR CORNELIUS PRE-MIX EQUIPMENT . . . . . . . . . . . . . . . . . . .
19
sanitizing special event equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
sanitizing jumpers and gas line assemblies (in-plant procedure) . .
22
EQUIPMENT REQUIRED FOR SANITIZING . . . . . . . . . . . . . . . . .
23
TROUBLESHOOTING
...............................................................
25
standard pre-mix dispensing valve . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
bar valve - five product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
SD 107
36