Popcake PC-10R User manual
Pancake Machine
Operating Manual
Model Series:
PC-10R/PC-11
CAUTION: Read the instructions before using the machine
Original Instructions
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i
INTRODUCTION 1
OVERVIEW 1
Popcake® – 97% fat free pancakes 1
The world’s first fully automatic pancake maker 1
Belt technology 2
SAFETY PRECAUTIONS 3
SAFETY HAZARD STATEMENT 4
QUICK REFERENCE GUIDE 5
INSTALLATION 7
MACHINE COMMISSIONING AND OPERATOR TRAINING 7
MIX AND BATTER 9
HYGIENE AND SAFETY RULES 9
BATTER PREPARATION RULES 9
Water temperature 9
Water volume 10
Bagged premix 10
BATTER PREPARATION PROCEDURES 10
Inspecting the bag 11
Adding water to the bag 11
Shaking the bag 11
Letting the bag stand 12
Preparing the bag for loading into the machine 12
CHANGING A BAG 13
Change bag procedures 13
MIX AND BATTER STORAGE,USE AND CARE RECOMMENDATIONS
15
Dry Powder - premix 15
Batter 15
Cooked pancakes 16
USING THE MACHINE 17
KEYPAD LAYOUT AND FUNCTIONS 17
EMERGENCY STOP 18
SPECIAL MESSAGES 18
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OPERATING MODES 19
Power up mode 19
Ready mode (making the pancakes) 19
Make mode 20
Cancel mode 20
Power down mode 20
MENU ITEMS 21
Change size 22
Change mix type 22
Change bag 23
Change color 24
Cake stack size 24
Mini stack size 25
Counter-Large 26
Counter-Medium 27
Counter-Minis 27
Input belt code 28
ERROR REPORTING 28
CLEANING AND MAINTENANCE INSTRUCTIONS
29
SAFETY RULES 29
CLEANING EXTERNAL SURFACES 30
BELT CLEANING PROCEDURE 30
SPLASH GUARD CLEANING 31
CLEANING OF THE CRUMB TRAY 32
CLEANING THE RUBBER WIPER LOCATED IN THE CRUMB TRAY
ASSEMBLY 32
CLEANING THE INTAKE FAN FILTER 33
CLEANING THE EXHAUST FAN FILTER 33
BELT CHANGING PROCEDURE 34
Removing a belt 34
Installing a belt 35
HOT PLATE ASSEMBLY REMOVAL PROCEDURE 37
Removing the hot plate assembly 37
Reinstalling the hot plate assembly 38
MANUFACTURER’S WARRANTY 39
FREQUENTLY ASKED QUESTIONS (FAQ) 39
CONTACTING US 43
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APPENDIX – FORMS 44
GLOSSARY 48
INDEX 49
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Popcake® – 97% fat free pancakes
Popcake®, pancakes are the world’s first
truly 97% FAT FREE pancakes.
Popcake® pancakes are made from
non-genetically modified natural
ingredients. Popcake® pancakes can be
served with a variety of delicious sweet
and savory toppings and fillings as well
as a variety of complementary food
items.
The world’s first fully automatic pancake
maker
Benefits:
Low maintenance with minimal cleaning in comparison to
conventional pancake cooking
Limited maintenance other than proprietary Teflon®-coated
belt changes. Belt changing is quick and can be done by the
end user very easily
User friendly menu-driven software that operates all functions
of the machine
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Mix bags:
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are strong and durable
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have a one way HACCP certified valve ensuring
freshness and helping to prevent bacteria cross-
contamination, and
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are specifically designed for the Popcake® machine
with obvious and easy operation
Exact measure of ingredients to eliminate waste and
shrinkage
Small “foot print” for commercial kitchens where space is a
premium
Conventional pancake cooking requires dedicated hot plates
whereas the Popcake® machine does not, even if change of
mix flavors is required
Very efficient power management
From an Occupational Health and Safety aspect, the machine
runs cool in all external, and the majority of internal, spaces
where an operator is likely to come into contact with the
machine and it is unlikely that injury will occur, in contrast to
conventional Pancake cooking that requires fat and heat
generated by gas or electricity.
No need for a kitchen exhaust system / range hood
Consistency and freshness of our pancakes
Belt technology
The machine utilizes two Teflon® belts specifically designed and
manufactured for the Popcake® Machine. The belts will operate
for the production of a minimum of 2,000 medium pancakes (or
equivalent) after which time the belts will need replacing. This
replacement function is simple and can be done by the end user.
The software will manage the detection and authentication of the
correct belt installation and prompt for new beltcodes, which are
needed when installing replacement belts to ensure continual
operation.
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Following are the safety measures when operating the machine:
1 This appliance can be used by children aged from 8 years
and above or by persons with reduced physical, sensory or
mental capabilities or lack of experience and knowledge if
they have been given supervision or instruction concerning
the use of the appliance in a safe way and understand the
hazards involved. Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by
children without supervision.
2 Young children should be supervised to ensure that they do
not play with the appliance.
3 Read all operating instructions before using machine.
4 Ensure to maintain this Operating Manual for future reference
by storing in a convenient place.
5 To prevent injury to persons and damage to the machine, use
only pancake mixes, belts and parts approved by
manufacturer and the correct measurement of water for the
mix.
6 Do not touch hot surfaces of the machine. These are clearly
labeled.
7 Do not operate the machine after a malfunction, or after it has
been damaged in any manner. Please Contact your
authorized distributor before using the machine for further
instructions.
8 This machine must be earthed. The manufacturer will not
accept any responsibility for injury to persons, animals or
damage to objects arising from non-compliance to this
requirement.
9 Ensure that the supply cord plug is easily accessible at all
times.
10 Keep the power cord away from hot surfaces.
11 Do not let the power cord hang over the edge of table or
counter, or touch hot surfaces.
12 Do not operate the machine if the power cord becomes
damaged for any reason.
13 If the supply cord is damaged, it must be replaced by the
manufacturer, its service agent or similarly qualified persons
in order to avoid a hazard.
14 Do not cover ventilation openings on the machine.
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15 The use of any accessory attachments not recommended by
the manufacturer may result in fire, electric shock or injury
and will void the manufacturer’s warranty.
16 The Popcake machine is not for outdoor use.
17 Do not place the machine on or near a hot gas or electric
burner, or a heated oven.
18 Do not heat, or use flammable materials in or near the
machine.
19 Do not use corrosive chemicals or vapors in machine.
20 Do not remove any panels or covers from the machine or
tamper with any working parts as it could result in serious
injury or death.
21 To protect against fire, electric shock and injury, do not
immerse the machine, cord or plugs in water or other liquid.
22 Do not use the machine for other than intended use.
23 Unplug the machine from power outlet when not in use and
before cleaning.
24 Allow the machine to cool down before cleaning.
25 The appliance is not to be cleaned with a water jet.
26 Use extreme caution when moving the machine.
27 [Symbol 5021 of IEC 60417-1] Equipotentiality.
28 Popcake pancakes are very hot when they come out of the
machine. To prevent injury, do not use your hand to handle
the Popcake pancakes as they exit the machine as they are
very hot.
29 Do not touch the exit of the hot conveyor.
30 With regards to airborne noise emissions, the A-weighted
sound pressure level is below 70 dBCA.
31 Any maintenance other than cleaning must be performed by
a qualified technician.
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This machine, was subjected to rigorous independent electrical
and mechanical safety standards testing, ensuring that all
machines are manufactured to those relevant standards and
accordingly the machine, does not represent a safety hazard to
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operators or other persons who may have cause to be in contact
with the machine, provided that;
1 The machine is correctly commissioned into the location
where it is used.
2 Operators report, through the management structure of their
organization, any and all malfunctions, injuries and injury
near misses together with details of the circumstances
leading to and surrounding the malfunction or incident.
3 All the various instructions, requirements and
recommendations detailed and outlined in this manual have
been read and understood, and are followed.
4 All error conditions reported by the machine are immediately
actioned in line with the instructions given on the machine
display and in this manual.
5 The machine is correctly maintained by operators in
accordance with the requirements detailed and outlined in
this manual and literature attached to the machine.
6 The machine is maintained by authorized distributors of the
manufacturer or their appointed service agents.
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For more detailed instructions on making pancakes, see:
1 “Batter preparation procedures” on page 10, then
2 “Change bag procedures” on page 13, and finally
3 “Ready mode (making the pancakes)” on page 19
4 For the very latest in training procedures, visit
www.popcake.com
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Before an operator can use the machine they must understand the
purpose of the machine, the way it functions and be well versed in
its operations. Training can take place directly by an authorized
distributor, by a person who has been trained and is qualified to
train others or by phone commissioning.
Every person who is to operate the machine should be trained
according to the following training schedule and such training
should be documented on the Operator Training Record provided
by the manufacturer. The form isavailable in the Appendix to this
Manual.
Alternatively, online training videos can be viewed at
http://www.popcake.com/training.php
Commissioning and training involves:
assessing the range of temperatures in which the machine
will operate
selecting an adequately ventilated location for the machine,
away from extremes of temperature, at an appropriate
distance from other heating sources and away from direct
sources of water
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leveling the machine
ensuring the machine is plugged directly into the power outlet
“without” the use of extension cords
explaining of the layout and content of this manual
identification of the machine’s working parts
explanation of how the machine works, including the function
of the operating computer software
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Hygiene is a vital part of ensuring the quality of the pancakes
served. When preparing the batter the following simple rules
should be followed:
1 Wash your hands thoroughly before commencing
preparation.
2 Rinse the water bottle in hot water before use.
3 Avoid direct handling of premix and batter
4 Wear correct attire (including gloves) to undertake the
preparation.
5 Make sure that the water being used is clean, fresh drinking
water at 72°F / 22°C.
6 Also ensure sharp items are out of the way when preparing
batter.
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Water temperature
Water temperature is very important to the way in which the raising
agents contained within the mix react. Always make sure to use
the temperature strip on your water bottle and get the water as
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close to 72°F / 22°C as possible. If you do not have a temperature
strip for your water bottle, please be sure to contact your
distributor. Using water that is too cold slows down the release
process and results in the release of agents after the bag of batter
has been loaded into the machine. This results in the bag burping
when pancakes are being made. This burping can affect the size
of the pancakes, but has no other effect.
NEVER USE COLD OR REFRIGERATED
WATER.
Water volume
It is vital in making pancakes of consistent texture and size to use
the recommended volume of water (655 ml / 22 fl oz). An excess
of water will produce a thinner batter and smaller, and more moist
pancakes. Insufficient water will give a thicker batter and larger
dryer pancakes. Volumes of water different to those recommended
can also lead to problems with cooking, batter spills, etc. Only use
the water bottle provided with the machine to ensure consistent
quality pancakes.
Bagged premix
Popcake® premix has been specially developed and blended
exclusively for use in Popcake® machines. Using any other premix
or batter, other than manufacturer branded premix, will result in
inferior tasting and inferior quality pancakes and will void the
manufacturer’s warranty of the machine.
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Preparation involves adding the recommended volume of water to
the bag of premix, mixing, allowing the mix to settle and releasing
build up of natural gases from the bag.
The Batter preparation procedures should be followed at all times
as outlined in this manual.
Failure to follow these procedures may result in the bag of
batter being the wrong consistency for cooking, which in turn
may lead to batter spills, cap blockages, etc. In the event of
batter spills, the machine may need to be cleaned and
servicing may be required.
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Inspecting the bag
1 Take a bag of premix from its storage place and inspect it for
any obvious signs of damage or rupture. Ensure that the cap
is correctly screwed to the bag nozzle. If it is damaged or
ruptured or the cap is not correctly screwed on, do not use it,
instead select another bag and repeat the inspection.
2 Open the lid of the cap and inspect it for any obvious signs of
damage, i.e. tears in the membrane. If the cap is damaged,
please call your authorized distributor for a replacement.
3 With the cap screwed on to the bag nozzle, take the bag in
both hands and gently knead the premix to loosen and blend
the ingredients evenly throughout the bag.
Adding water to the bag
1 Unscrew the cap on the bag nozzle and place the bag on a
flat surface ensuring that none of the premix is dislodged
from the bag. Place the cap lid down in a clean, convenient
position.
2 Using the water bottle provided, fill the water bottle to the top
with clean, fresh, drinking water at 72°F/22°C as displayed on
the temperature strip. Insert the top attached to the bottle into
the neck of the bottle and displace the excess water.
If the bottle is lost, do not use another vessel. Please
call your authorized distributor for a replacement bottle.
3 In one hand, pick up the bag by the nozzle and using the
other hand pick up the filled water bottle. Pour the water from
the water bottle into the bag, being very careful not to spill
any of the water.
4 Pick up the cap and screw it back on to the bag nozzle,
ensuring that it is threaded correctly and not cross-threaded.
5 Always dry the outside of the bag with a clean, dry cloth to
ensure the machine itself is kept clean and dry once the bag
is loaded into it.
Shaking the bag
1 Holding the bag at the opposing corners (on the longest side
of the bag) vigorously shake the bag back and forth for 20-30
seconds.
2 Flip the bag over, holding the opposite two corners and
vigorously shake back and forth for an additional 20-30
seconds.
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3 Slap the bag down onto a flat surface, making sure that the
nozzle is facing upwards twice or three times to infuse air
bubbles into the batter.
4 As the contents of the bag are mixed, the bag fills with the
raising agent’s natural gasses.
5 Unscrew the cap to release the air built up inside the bag.
6 Gently move a hand across the surface of the bag to ensure
that as much air as possible is removed from the bag.
7 Screw the cap back onto the nozzle.
Letting the bag rest
1 After concluding steps 1 - 7 above, let the bag rest (cap
facing up) for a minimum of three (3) minutes.
2 Once the bag has rested, repeat steps 1 – 7 above.
Preparing the bag for loading into the
machine
This part of the procedure should be performed immediately before
you load the bag into the machine.
1 Unscrew the cap and check that the nozzle of the bag is clear
of blockages then correctly screw the cap on the nozzle being
mindful not to cross thread.
2 Ensure that dry premix has not accumulated in the corners of
the bag as this may cause difficulties when loading the bag
into the bag chamber. If there is premix or batter accumulated
in the corners, hold the corner of the bag between the thumb
and the first two fingers and gently rub until it is removed or a
sufficient amount is removed to ensure that no problems will
be encountered when loading the bag into the bag chamber.
3 Take the bag that is to be loaded into the bag chamber and
remove and discard the hinged lid from the cap by twisting
the lid to one side until the hinge tears and breaks off.
Dispose of the lid responsibly.
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4 Load the bag into the machine following the instructions on
the control panel.
Change bag procedures
You may only use the manufacturers mix that has been
prepared in accordance with the Mix Preparation Procedures.
No other bagged batters or premixes of any kind should be
used in this machine. Failure to comply will result in possible
machine failure and the manufacturer’s warranty being voided.
Bags may be loaded or changed under the following
circumstances:
You are turning the machine “on” or “off” and you need to
load or unload a bag.
The machine detects that a bag change is required because
the bag of batter is empty.
You choose to change the bag, for some other reason,
It is important that you understand and follow the instructions
shown on the machine display. If you are uncertain, refer to “Using
the machine” on page 17 of this manual.
Always follow the instructions in “Hygiene and safety rules” on
page 9 when loading and unloading bags.
Loading a bag into the machine
1 When the lid of the machine is opened and the bag chamber
is empty, take the bag of batter in both hands (one on each
side of the bag nozzle) and place the nozzle down into the
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hole of the splash guard which is located in the floor of the
bag chamber. Let the body of the bag lie on the floor of the
bag chamber.
2 Slowly feed the batter away from the tail end of the bag by
gently squeezing the batter up toward the middle of the bag
and insert the tail of the bag between the two rods located in
the bag chamber. It may be easier to first insert one side of
the tail and then pull the rest of the tail through between the
rods into position. Ensure that the bag is parallel with the
sides of the chamber and that the bag tail is pulled as far
through between the rods as is practical.
3 Using your hand gently distribute the batter evenly through
out the bag.
4 Slowly lower the lid of the machine. To close the lid, lift the
latch and then release it. You should hear an audible click.
You should not need to apply any force to the lid or latch
to close the machine.
5 If an inflated bag prevents the lid from closing easily, remove
the bag, slap the bag down onto a flat surface, release the
built up gasses and then reload the bag.
6 Once the lid is closed, follow the instructions on the control
panel display.
Unloading a bag from the machine
1 Following the instructions shown on the machine display,
open the lid of the machine and remove the bag. Upon
opening the lid, the bag will be seen in the bag chamber with
the bag nozzle located on the hole in the floor of the
chamber.
Remove the bag from the machine by firstly pulling the tail of
the bag out from between the rods and then using both
hands, one on each side of the bag nozzle, pull the nozzle up
out of the hole in the floor of the bag chamber.
2 If the bag removed from the machine is empty dispose of it
responsibly or if it still contains usable batter store the bag in
line with the “Mix and batter storage, use and care
recommendations” on page 15.
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Dry Powder - premix
Storage
Boxes and individual bags of premix should be stored in a cool
and dry place out of direct sunlight for a maximum period of 12
months from the manufacturing date. Although the bags are sealed
with caps, moisture could enter the premix through the caps if it is
not correctly stored.
Boxes can be stored in stacks, however, avoid making stacks too
high as they can become unstable and collapse, causing damage
and/or injury.
Stock rotation
A system of stock rotation should be implemented which ensures
that the older stock is used first.
Allergens
Our premix contains some allergens AND should be handled with
care. Please check packaging for details.
Carrying and handling
Your internal OHS regulations must be followed when carrying and
handling boxes of premix.
Bags of premix or batter should be handled with care. They should
not be thrown, ruptured or abused in any way. The premix and
batter contains some allergens (see packaging for details). These
could cause allergic reactions in some people if they were exposed
to it or inhale it.
Batter
Storage
Bags of batter have a recommended life of eight 8 hours from the
time of mixing the premix with clean, fresh drinking water, provided
that the batter temperature remains below 90°F / 32°C. Use of
bags of batter above 90°F / 32°C is not recommended.
Bags of batter must not be left in the machine bag chamber
overnight or when the machine is not in use.
This manual suits for next models
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