Daily Cleaning: Steps for Disassembling and Washing an Encrusting Machine

Why Disassemble and Wash Every Day?

Dough and fillings are a favorite food source for microorganisms. If even a little residue is left in a corner of the hopper, a gap in the screw, or inside the nozzle, one night is enough for bacteria to multiply. When the machine starts up the next day, that residue goes into the first batch of product.

Annex 2 of the Regulations on Good Hygiene Practice for Food (食品良好衛生規範準則) requires equipment and utensils to be cleaned thoroughly after use and protected from recontamination, with food-contact surfaces kept smooth, free of dents or cracks, and clean; cleaning and sanitizing must prevent detergents or sanitizers from contaminating food-contact surfaces. Applied to an encrusting machine, these rules mean disassembly and washing every day.

RHEON's Japanese FAQ answers that the machine's parts are easy to remove, so cleaning is simple, and a washer can also be used. This reflects the basic design philosophy of encrusting machines: food-contact parts must be removable for washing.

General Washing Steps

The general process for a typical encrusting and forming machine is as follows; actual steps and removable parts depend on each model's manufacturer's manual:

1. Stop, cut power, lock out and tag out: Turn off and lock the power and hang a "Cleaning in progress" sign so no one starts it accidentally. This is required by Article 57 of the Occupational Safety and Health Facilities Rules (職業安全衛生設施規則); see Cleaning Safety: Stop, Cut Power, Lock Out for details.
2. Clear residue: Remove leftover dough and filling from the hopper, and scrape off large pieces of residue with a scraper. Handle leftover material according to your own rules; don't return it to the raw material area.
3. Remove parts: In order, remove the hopper, screw or feed parts, nozzle, cutting parts, scrapers, and seals. Place removed parts on clean trays or racks, not directly on the floor.
4. Pre-rinse: Rinse off surface dough and fat with warm water. Water that's too hot may make proteins stick to the surface and become harder to wash, so adjust according to the type of soil.
5. Scrub with detergent: Use a food-grade cleanser with a soft brush or non-woven pad to scrub every crevice. Avoid steel brushes; shed bristles become metal foreign matter and also scratch surfaces.
6. Rinse with clean water: Rinse off all detergent completely.
7. Sanitize: Choose hot water or a compliant sanitizer according to the product and standards. For sanitizer concentration and whether a rinse is needed afterward, see Choosing Detergents and Sanitizers.
8. Dry: Drain or blow-dry on a ventilated rack; don't wipe with dirty cloths.
9. Clean the machine body: Clean the housing, control panel, and underside of the machine with a damp cloth or by methods the manufacturer permits.
10. Reassemble or store separately: Some factories reassemble at the end of the day, while others dry the parts and store them separately, reinstalling them before start-up the next day. Either way, check before start-up; see Pre-Start Checklist.

Which Parts Should Be Removed?

The principle is that "all food-contact parts, and every passage food flows through," should be removed. Parts commonly removed on encrusting machines include: the hopper, feed screw or vanes, filling and dough feed passages, nozzle, cutting or forming parts, scrapers, and seals. The conveyor belt surface must also be cleaned, and removed for washing if it's detachable.

Parts not to remove: the electrical control box, motor, and inside of the drive mechanism. Unless you're doing maintenance, don't open these during daily cleaning.

Can It Be Rinsed with Water?

It depends on the model and the part. Some models have food-contact areas designed to be washable; for example, Rheon USA's product description for the KN551 states it can be cleaned with running water. But if water gets into the electrical box, motor, control panel, or bearings, it may cause short circuits or rust.

General principles:

• Removed parts: can be washed with water in a wash sink.
• Machine body: Follow the manufacturer's instructions; usually it's wiped with a damp cloth. Even if labeled washable, avoid spraying high-pressure water directly at electrical parts.
• Floor: When hosing the floor, keep splashes away from cleaned parts and the machine's electrical parts.

How Long Does It Take?

It varies by model, product, and staff proficiency, so there's no fixed time. Factors include the number of parts to remove, how sticky the product is (mochi and very sticky fillings are harder to wash), and how well equipped your washing setup is. Time it the first time, write the steps into a standard operating procedure (SOP), and then optimize. For cleaning when changing products, see also Product Changeover Steps and Time.

FAQ

Q: Does an encrusting machine really need to be disassembled and washed every day?
A: Yes. Leftover dough and filling can let bacteria multiply overnight, so food-contact parts must be disassembled and washed every day.

Q: Can I hose down the whole machine?
A: Not recommended. Removed parts can be washed with water, while the machine body and electrical parts should follow the manufacturer's instructions, usually wiped with a damp cloth.

Q: Can I scrub parts with a steel brush?
A: Not recommended; shed bristles may become metal foreign matter and also scratch surfaces.

Q: Where can I find the disassembly and washing steps for Dong-Yih models?
A: Follow the instructions supplied with your machine, or call us at 06-257-4644.