FREQUENTLY ASKED QUESTIONS

EQUIPMENT

Firstly, you should think about where you will make & sell Kurtoskalacs.
Will you be a mobile vendor & visit different festivals & events or will you be a ‘static’ vendor & stay in one fixed location?

We would normally suggest that ‘static’ vendors use an ELECTRIC appliance. The main reason for this is that the electric appliances do require a lot of power & if you are mobile, you might not be guaranteed the correct power supply at every event (different locations) you go to.
Electric appliances really need to be plugged into a mains electricity supply which is stable & where the appliances will receive the correct voltage & amperes.
The Electric appliances should not be connected to long electrical extension cables as this can result in voltage drop. Often at events you will be offered power from a cable that is far away from the actual mains supply. Also, several vendors could be running their machinery off the same cable & as (for example) the ELECTRIC OVEN 8 is rated at 13 amperes the fuse or circuit breaker could easily be overloaded which could result in the circuit breaker activating or fuse blowing & cutting off the power to the oven.
Some customers have asked if they could use a generator to power an electric oven, the answer is yes, but first you need to speak to your generator supplier to ask about which size generator you would require. Usually generators of the required power output are large & very expensive.
Therefore, we always recommend our GAS appliances to customers who want to be mobile. The Gas appliances are set up to work on bottled LPG gas. The gas appliances do however require electricity to power the motors which rotate the Chimney Cake during baking & also to power fans which cool the motors. However, the electrical consumption for this is very low, less than 100 watts. You can plug into the mains electrical supply, plug into a generator or you can connect to a re-chargeable, deep cycle battery through a transformer or inverter which will drop the voltage to 12v.

We manufacture all our equipment in either 230v or 120v. You should choose the machine’s voltage which matches the voltage which your country uses. The exception is the ELECTRIC OVEN 12 . This oven is built for Europe & requires a 400v three-phase supply, therefore it can only be used at a facility which has a three-phase supply.

We make three different ELECTRIC appliances in 120v.

Electric oven – 4 digital
Electric oven – 8 ECO digital
Electric grill – 6 ECO digital
   The Electric 4 & 8-piece ovens & the Electric grill 6 are SINGLE-PHASE machines.
   The Electric oven 4 digital 120v requires 15 amps & is fitted with a NEMA 5-15 plug.   The Electric oven 8 Eco digital 120v requires 30amps & is fitted with a heavy duty NEMA
L5-30 twist lock plug.   The Electric grill 6 Eco digital 120v requires 30amps & is fitted with a heavy duty NEMA
L5-30 twist lock plug.If you are looking to install the Electric oven 8 Eco digital 120v or the Electric grill 6 Eco
digital 120v at your facility you need to:(a) Ensure that the fuse board has a 30amp fuse or circuit breaker installed to support the
machine.
(b) Ensure that the cable going from the fuse board to the socket where the oven will be
plugged in is the correct thickness or gauge to support the machine.
(c) Install the correct electrical outlet socket (receptacle) which enables you to plug in the
machine with the heavy duty NEMA L5-30 twist lock plug.
A professional / qualified Electrician should be instructed to carry out the above-mentioned
tasks.CASE STUDY: We had a situation in the past whereas we had a customer located at a
semi-permanent market. Inside our customer’s booth there was a fuse board/consumer
unit with 3 x 20 amp fuses on different circuits.The organiser of the market would not install a 30amp fuse in the fuse board or install a
socket which would enable the customer to plug in an Electric oven 8 ECO digital 120v oven.In the end, to solve this issue, the customer purchased 2 x ELECTRIC OVEN 4 DIGITAL (which require 15amps each) & connected them both to different circuits.

The GAS OVEN 8 cannot run on natural gas. However, the infrared burners we install on the GAS GRILL 8 are manufactured to be used with both LPG & LNG (natural gas). Please note, the orifice hole drilled in to the gas nozzle which the gas travels through to the burner is bigger for natural gas. This is because natural gas operates at a lower pressure. If you wanted to connect a Gas grill 8 to mains natural gas, then we would need to know what the gas pressure is at the connection point. We can then fit the correct size nozzle so that the burners receive the correct amount of gas to burn correctly & efficiently. When the grill arrives, you would then need to get a qualified gas engineer to run piping from the gas supply to the GAS GRILL 8. All gas installations must comply with local laws & standards.

Believe it or not we are asked this question quite a lot as some people assume that you must stand over the grill or oven & manually turn the COOKING ROLLS next to the heat source, this is not the case. Inside every machine we manufacturer there are a set of motors, one motor for each baking point. For example, the Electric oven 4 contains 4 motors where as the Gas grill 8 has 8 motors inside. With all our machines, as soon as they are turned on, all the motors start to rotate. Theadvantage of having one motor for each baking point, is that if one motor fails during operation you still have the remaining baking points to work with until you have the time toreplace the motor, unlike some other machines on the market which have just one motor & a drive chain. In the case of this type of machine, if the one motor breaks, the wholemachine will be out of order until the motor is changed. If the cooking rolls are removedcorrectly from the oven / grill, they should last a fair while. Motors generally fail due to user
misuse.

The GAS OVEN 8 cannot run on natural gas. However, the infrared burners we install on the GAS GRILL 8 are manufactured to be used with both LPG & LNG (natural gas). Please note, the orifice hole drilled in to the gas nozzle which the gas travels through to the burner is bigger for natural gas. This is because natural gas operates at a lower pressure. If you wanted to connect a Gas grill 8 to mains natural gas, then we would need to know what the gas pressure is at the connection point. We can then fit the correct size nozzle so that the burners receive the correct amount of gas to burn correctly & efficiently. When the grill arrives, you would then need to get a qualified gas engineer to run piping from the gas supply to the GAS GRILL 8. All gas installations must comply with local laws & standards.

In our opinion the more COOKING ROLLS you have the better!

We recommend that you have at least three sets of cooking rolls in relation to the size of your Kurtoskalacs baking machine. Therefore, if you have a 4 piece-oven, we suggest 12 rolls. For an 8-piece Chimney cake baking machine we suggest 24 rolls. If you have an 8-piece baking machine & want to make both standard size & cone size Kurtoskalacs then we suggest 24 of each type so 48 rolls in total.

When our customers ask us about the production capacities of our ovens or grills we always explain that it’s usually not the baking capabilities of the machine which determines how many Kurtoskalacs you can produce BUT the volume of Chimney cakes that is supplied to the oven or grill. This means that it’s down to the person or people rolling the dough strip onto the cooking roll. If the person rolling the dough onto the cooking roll is having to wait for fresh wooden rolls then the production line will slow or stop. Delays can happen when, for example, some rolls are being used for the actual bake, some are waiting to be cleaned & some have dough on them which is rising & not ready for baking yet. Having many rolls means that dough can be prepared in advance which ensures the grill or oven is never empty!

There are two purposes of the COOKING ROLL RACKS. The first is that you will need an organised & convenient place to store the cooking rolls when not in use. This will ensure that the rolls can be easily handled during production.

The second purpose is that after you have rolled the dough onto the cooking roll you will need to leave the dough to rise on the roll before baking. This is to enable air to circulate around the dough area & to ensure that the dough is not touching anything else. The cooking roll racks are ideal for this purpose.

We make roll surface racks & roll wall racks. The advantage of surface racks is that they can be easily moved around but please bear in mind that they could take up valuable work space.

We would always recommend the roll wall racks to customers who have suitable walls to fix them to, especially those who will be working from inside a food truck / trailer which may have limited space. Valuable work surface space is left free if wall racks are attached to the walls. We also think that the wall racks (especially when cooking rolls with dough are placed on them) are a good way to market & promote your business as curious customers are often drawn towards them to see what they are!

The size of kneading machine will depend on the amount of dough you wish to knead in one bowl. It’s important to know that when dough is made it should be used within 3 to 4 hours so that it’s at its best. Therefore, you should aim to knead several batches in one day according to the amount of hours you plan to be operating. If the machine is too big you will struggle with kneading a small batch of dough as a lot of flour or the other dry ingredients can be left stuck to the bottom & will not be combined in the dough. If the dough kneading machine is too small you will be kneading many batches of dough which is an un-economical use of your time.

We recommend that you obtain a 15 to 20 litre kneading machine.

There are also two types of kneading machines. One type has a fixed bowl & the other has a bowl that is detachable. We suggest you use a “Planetary mixer”. This type has a detachable bowl & usually have two or three different speed settings.

The main reason for recommending this type of kneading machine is that it is much easier to use & to clean. We have also seen that a lot of the kneading machines with the fixed bowls have just one speed., “slow”.

There is also an active second-hand market for kneading machines so consider checking out online selling sites such as eBay!

As you will have seen on our web site we make & supply COOKING ROLLS made from either Beech wood or food grade stainless steel.

Traditional rolls are made from Beech wood, but we started manufacturing stainless steel rolls as the certification company we use, NSF International informed us that they would not certify any equipment used in the food process industry that is made from wood. They would however certify the rolls if they were made from food grade stainless steel.

If you ask a food inspector in any country in the world, “which rolls should I use, wood or steel?” I guarantee that you will be told to use the stainless-steel rolls, however we have sold thousands of wooden rolls all over the world & none of our vendors have been ever been told to stop using them.

Our personal preference is to use the wooden rolls for the sweet Chimney Cake & the stainless-steel rolls for the savoury version of Kurtos. The reason is that when we make savoury Kurtos we add olive oil, herbs, garlic, salt etc & the smell & taste is difficult to remove from the wooden rolls. With regards the stainless-steel rolls you can completely submerge them in water & scrub them clean or you can clean them in a dishwasher.

Finally, when using wooden rolls, you should cover as much of the wooden roll surface as possible with dough. Large exposed areas will darken & burn after time. If you use the stainless-steel rolls, exposed areas will not burn & can be cleaned more thoroughly.

The cooking area of the WOODEN ROLL is made from natural, untreated Beech wood. This means that no varnish or chemicals have been used on the wood.

When you receive the wooden rolls, they are new & unseasoned therefore, the first thing that you MUST do is season the wood. If you don’t the dough will stick to the roll after baking. The dry wood will also ‘suck’ out the moisture from the dough during the baking resulting in a dry baked dough. The unseasoned wood will also crack & splinter over time.

To season the wooden roll, you simply paint the wooden cooking area all over with cooking oil such as sunflower oil. It is important to include the end parts of the rolls. To ensure that the oil soaks into the wood you should do this a few times per day for around 3 days. Some customers tell us that they pour the oil into a bucket & completely submerge the rolls into the oil for 24 hours so that the wood fully absorbs the oil.

Since the wooden rolls are subjected to extreme heat, water & oil several times per day, the wooden cooking area will crack over time. You will usually see signs of cracking after only a small amount of use, however the cracking will settle down. It’s rare that a wooden roll will completely crack from end to end.

Finally, when using wooden rolls, you should cover as much of the wooden roll surface area as possible with dough. Large exposed areas will darken & burn after time.

The stainless-steel cooking rolls can be soaked in water or cleaned inside a dishwasher due to the nature of the material they are made from. As they are hollow, a bottle brush can be pushed inside to clean the inside of the cooking roll. Normal washing detergent can be used.

When you clean the wooden cooking rolls you should wash then under clean, running water & not submerge them in water. If you do, the wood will absorb too much water & the rolls will swell & finally crack. Also, during the baking process, water which was absorbed can be released resulting in soggy & unbaked dough. During production, it is sufficient to wipe the rolls in between baking with a clean, hot, wet cloth, then at the end of the baking day, clean more thoroughly.

We stock & sell spare parts for all our machines & offer a comprehensive after sales technical support service. Some customers have changed parts themselves as in most instances it is a straight forward job. A general appliance repair engineer would be able to make repairs for you if you are unsure of your own technical abilities. When dealing with gas we always suggest that you use a qualified gas repair service so that the appliance can be tested properly for gas leaks after the part has been changed & before the machine is used again.

Some customers do ask to purchase essential spare parts when they purchase their equipment to keep as spares at their facility where the machine will be in use.

The electrical heating elements inside the Electric machines are consumable parts. This means that they will need changing after a period of usage time. They are rated for 2500- 3000 working hours.

Motors generally break due to incorrect use by the user. If the user is not removing the cooking roll correctly from the machine or the user is holding onto the cooking roll for too long when it is rotating it can result in damage to the motors.