Package for Hospitality Training

(Including Competency Standard, Teacher Focused & Student

Centered Materials and Assessment Tools)

Unit Title:
OPERATE CELLAR SYSTEMS

Unit Code: ITHHBFBS05AEM

Acknowledgements

Indonesian Hotels and Restaurant Association

Jakarta International Hotels Association
Ministry of Manpower and Transmigration
Ministry of National Education
Ministry of Culture and Tourism
Tourism Training Australia
Australian National Training Authority
Australian Agency for International Development

This package has been produced to provide information that can be used to
complement the materials that already available. The package is not intended
to replace current resources.

Package for Hospitality Training – Operate cellar systems i

Glossary

Access and equity

Refers to the fact that training should be accessible to everyone regardless of age, gender,
social, cultural, religious or educational background.

Assessment
The formal process ensuring training meets the standards required by industry. This process
is performed by a qualified assessor within a nationally agreed framework.

Assessor
An assessor is a person who is certified by industry to assess whether a worker is competent
to undertake specific tasks.

Competent
Able to do the job and has all the necessary skills, knowledge and attitude to perform
effectively in the workplace, according to agreed standards.

Competency Based Training

Training that relates to what people must be able to do and measures performance against
agreed standards.

Critical aspects of assessment

Explains the central point of the assessment and the key points to look for when assessing.

Context of assessment
Specifies where, how and by what methods assessment should occur.

Elements
The skills, which make up a unit of competence.

Evidence guide
These are guidelines on how a unit should be assessed.

Fair
Does not disadvantage particular trainees or students.

Flexible
Acknowledges that there is no single approach to the delivery and assessment of
performance in a competency-based system.

Formative assessment
These are small assessment tasks done during training. They assist in making sure that
learning is taking place and also give the trainees or students feedback on their progress.

Key competencies
Competencies that underpin all work performance. These are: collecting, analysing and
organising ideas and information, communicating ideas and information, planning and
organising activities, working with others and in teams, solving problems, using technology,
using mathematical ideas and techniques.

Package for Hospitality Training – Operate cellar systems ii

These competencies are graded in different levels.
Level of ability to be demonstrated in achieving the key competencies
Level Characteristics
1 Undertakes routine tasks within established procedures and is subject to
frequent progress checks by supervisor.
2 Undertakes broader and more complex tasks with increasing personal autonomy
for own work. Supervisor upon completion checks work.
3 Undertakes complex and non-routine activities, is self directed and responsible
for the work of others.

Linkages to other units

Describes the role of the unit and its place within the full set of competencies specified by
industry. It provides guidance as to which units may be assessed together.

National competency standards

Nationally agreed statements of the skills and knowledge that people need at work and the
standards of performance that are required.

Performance criteria
This is used to judge whether an individual has achieved competence in a unit.

Range of variables
This details the range of different contexts that may apply to a particular unit.

Reliable
Uses methods and procedures that confirm that the competency standards and their levels
are interpreted and applied consistently in all contexts and to all trainees or students.

Standards and certification institute

Ministry of Manpower and Transmigration (MOMT) has given authority to Indonesian Hotels
and Restaurants Association (PHRI) and Association of Indonesian Tours and Travel
Agencies (ASITA) to establish the Institute for the Standardisation and Certification of the
competency of Indonesian workers in the hospitality and tourism industry. The institute will
develop competency standards and information systems for the Standardisation and
Certification of competencies as well as administer competency tests and certify Indonesian
workers in the hospitality and tourism industry.

Summative assessment
The assessment done after training of the completed unit of competence to ensure that
trainees or students have achieved the performance criteria.

Trainee or student
A trainee or student is a person who is being taught knowledge or skills.

Trainer or teacher
A trainer or teacher is a person who facilitates learning.

Underpinning skills and knowledge

Defines the skills and knowledge required to be competent at the specified level.

Unit descriptor
A general description of the competency standard.

Valid
Judgement on the same evidence and criteria

Package for Hospitality Training – Operate cellar systems iii

will produce the same assessment outcomes
from different assessors.

Package for Hospitality Training – Operate cellar systems iv

 Table of Contents
1. Introduction to this guide
1.1 Introduction______________________________________________1
1.2 Time required to achieve competency__________________________1
2. Help for the trainer or teacher
2.1 The role of the trainer or teacher______________________________2
2.2 Delivery strategies_________________________________________2
2.3 Delivery requirements______________________________________2
2.4 Sources of additional information_____________________________2
3. The competency standard
3.1 Use of the competency standard______________________________4
3.2 Competency standard______________________________________4
4. Delivery strategy
4.1 The content plan__________________________________________6
4.2 How to teach the competency standard_______________________10
4.3 Support materials (Overhead transparencies/Handouts)__________15
5. Assessment
5.1 Workplace assessment issues______________________________64
5.1.1 Workplace assessment.....................................................................64
5.1.2 Competent.........................................................................................64
5.1.3 Recognition of Current Competence.................................................64
5.1.4 Assessors..........................................................................................64
5.2 Underpinning skills and knowledge___________________________64
5.2.1 Assessment of underpinning skills and knowledge...........................64
5.2.2 Examples of assessment tasks.........................................................65
5.3 Suggested assessment for Operate cellar systems______________65

Appendices
1 Competency assessment result.
2 Group trainee or student assessment record.
3 List of overheads and handouts.
4 Trainee or student evaluation sheet.
5 Amendment list.
Section 1
Introduction to this guide
1.1 Introduction
Welcome to this guide.

This guide uses Competency Based Training to teach workplace skills. It is based on
competency standard that is a nationally agreed statement of the skills, attitude and
knowledge needed for a particular task. The major emphasis is on what an individual can do
as a result of training. One of the most important characteristics of Competency Based
Training is its focus on training individuals for actual jobs in the workplace.

This will help you teach the competency Operate cellar systems.

This guide deals with the skills and knowledge required to operate dispensing and quality
control systems within a cellar.

Linkages to other units:

1.1 This unit should be assessed with or after Unit ITHHGGA06AES – Receive and store
stock.
1.2 In some industry contexts this unit may be linked to Unit ITHHBFBS01AES – Operate a
bar and combined assessment/training may be appropriate.

Care should be taken in developing training to meet the requirements of this unit. For general
and prevocational training, organisations providing training which takes into consideration the
full range of industry contexts, with no basis towards individual sectors. The Range of
Variables will assist in this regard. For sector-specific delivery, training should be tailored to
meet the needs of that sector.

Teachers and trainers should structure their sessions according to the:

 needs of their students/trainees
 requirements of their organisation
 time available for training
 training situation.

A delivery strategy has been provided for the teachers and trainers. The suggested content
gives an indication of what needs to be covered in the program to meet the competency
standard.

The delivery strategy used and assessment provided in this unit is not compulsory and should
be used as a guide. Teachers and trainers are encouraged to utilise their own industry
knowledge, experience, local examples and products to adapt the materials or develop their
own resources, in order to ensure the relevance of the training.

1.2 Time required to achieve competency

Under Competency Based Training, the focus should be on achieving competence, not on
fulfilling a particular time requirement, as different trainees may take different lengths of time
to be competent in a particular skill.

Package for Hospitality Training – Operate cellar systems 1

Section 2
Help for the trainer or
teacher
2.1 The role of the trainer or teacher

One of your roles as a trainer or teacher is to ensure high standards of service through
effective training. To ensure that you are ready to start working on this competency with
trainees or students, consider the following questions:
How confident do you feel about your own knowledge and skills required to deliver each
element?
Is there any new information or laws that you may need to access before you start training?
Do you feel confident about demonstrating the practical tasks?
Will you be able to clearly explain the underpinning knowledge that your trainee or student will
need to do the job properly?
Are you aware of the scope of industry situations in which the competency may apply?
Are you aware of the language, literacy and numeracy skills your trainees or students need to
demonstrate competency in this standard?
Have you consider access and equity issues in planning the delivery of this training program?

2.2 Delivery strategies

The range of training activities that has been suggested for delivering this competency may
include:
 actual tasks
 projects and assignments
 case studies
 lectures
 videos and references
 group activities
 role plays and simulations.

Trainers or teachers should select training strategies that are appropriate for the competency
being taught, the situation and the needs of the learners. For example, if practising on-the-job
is not possible, varied simulations and role-plays may be appropriate.

2.3 Delivery requirements

Classroom space for delivery to trainees, whiteboard / blackboard, overhead projector,
overhead projector screen, flip chart, flip chart paper and multimedia.

2.4 Source of additional information

Sources of information may include some of the following categories:
 text books
Ellis, G
The Australian Bar Attendants Handbook
Hospitality Press
1998
Melbourne, Australia

Hastings, D
Spirits & Liqueurs of the World

Package for Hospitality Training – Operate cellar systems 2

 Revised edition 1984
Footnote Productions
London, UK

Howard, P & Puckerirdge J

The Professional Bar Attendant
Hospitality Education Services
1994 (2nd Edition)
Sydney, Australia

UK Bartenders guild
International Guide to Drinks
Century Publishing
1988
London, UK

 professional journals
 Tourism Training Australia website: www.tourismtraining.com.au
 Industry Associations – Indonesian Hotels and Restaurants Association (PHRI)
Jl. R.P Soeroso 27 GHI (Gondangdia Lama) Jakarta 10350
Phone: (021) 310 2922
 Teacher Associations - PPPG
Jl. Raya Parung KM.22-23 Bojongsari, Sawangan – Bogor
Phone: (021) 743 1271

Package for Hospitality Training – Operate cellar systems 3

Section 3
The competency
standard
3.1 Use of the competency standard
In a training situation the competency standard assists the trainer or teacher to:
 identify what trainees or students have to do
 identify what trainees or students have already done
 check trainees’ or students’ progress
 ensure that all elements and performance criteria in training and assessing are
covered.

3.2 Competency standard

UNIT ITHHBFBS05AES OPERATE CELLAR SYSTEMS

UNIT DESCRIPTOR This unit deals with the skills and knowledge required to operate
dispensing and quality control systems within a cellar.

ELEMENTS PERFORMANCE CRITERIA

01 Operate and 1.1 Bulk dispensing systems are correctly operated in
maintain bulk accordance with manufacturer's instructions and safety
dispensing systems requirements.
1.2 Temperature, carbonation and pump pressure are
monitored.
1.3 Connectors, extractors and heads are cleaned
hygienically.
1.4 Nitrogen and integrated systems are set up safely and
correctly to manufacturer's specifications.
1.5 Faulty products and product delivery problems are
promptly and accurately identified.
1.6 Faults are promptly corrected or reported to the
appropriate person.
02 Operate and 2.1 Beer reticulation systems are correctly operated and
maintain beer cleaned in accordance with manufacturer's instructions.
reticulation 2.2 Safety procedures regarding handling, connecting and
systems storing of gas are strictly followed.
03 Use and maintain 3.1 Refrigerator temperatures are measured accurately and
refrigeration adjusted to comply with product requirements.
systems 3.2 Refrigerator seals and catches are maintained to
manufacturer's specifications.
3.3 Refrigerator vents, coils and filters are cleaned to
manufacturer's standards.
3.4 Walk-in cool room alarms are set and re-set when
required and to manufacturer's specification.
3.5 Basic mechanical faults are recognised and immediately
repaired, or reported in accordance with enterprise
procedures.
04 Monitor quality of 4.1 Quality of cellar products is regularly tested and faults
cellar products identified.
4.2 Adjustments are made within scope of individual
responsibility or faults are reported to the appropriate
person.
4.3 Follow up action is taken to ensure faults are rectified.
4.4 Bin and keg card systems are used to assist in
monitoring the quality of products and controlling stock.
4.5 Cellar is kept tidy, clean and free from litter.

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 4.6 Cellar temperature is monitored.
RANGE OF VARIABLES
1. This unit applies to all establishments, which maintain a cellar.
2. Bulk dispensing systems may include systems for:
2.1 beer
2.2 spirits
2.3 wine
2.4 post-mix spirits.
3. Cellar products may include but are not limited to:
3.1 beers (bulk and packaged)
3.2 wines
3.3 spirits
3.4 liqueurs
3.5 aerated and mineral water
3.6 post-mix
3.7 juices and syrups.
4. Refrigeration systems may include but are not limited to:
4.1 portable systems
4.2 cold rooms
4.3 cabinets
4.4 instantaneous coolers.

EVIDENCE GUIDE
1. Underpinning skills and knowledge
1.1 To demonstrate competence, evidence of skills and knowledge is required in
cellar products) as defined above) and their characteristics including:
a. potential faults
b. shelf-life
c. correct handling and storage
d. potential dangers of working with gas and pressure
e. specific cellar safety requirements.
2. Context of assessment
2.1 This unit must be assessed through practical demonstration on-the-job or in a
simulated service environment where the relevant equipment is provided. This
should be supported by assessment of underpinning knowledge.
3. Critical aspects of assessment
3.1 Evidence should include a demonstrated knowledge and understanding of the
safety requirements for operating cellar equipment and of the quality issues that
affect beverages. It should also include a demonstrated ability to operate
equipment within those safety requirements.
4. Linkages to other units
4.1 This unit should be assessed with or after Unit ITHHGGA06AES - Receive and
store stock.
4.2 In some industry contexts this unit may be linked to Unit ITHHBFB01AES -
Operate a bar and combined assessment/training may be appropriate.

KEY COMPETENCIES IN THIS KEY COMPETENCIES IN THIS

LEVEL LEVEL
UNIT UNIT

Collecting, organising and Using mathematical ideas and

1 1
analysing information techniques
Communicating ideas and
1 Solving problems 1
information
Planning and organising
1 Using technology 1
activities
Working with others and in 1

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 teams

Package for Hospitality Training – Operate cellar systems 6

Section 4
Delivery Strategy
4.1 The content plan
Note: In delivering the training below, teachers, trainers, trainees, students and assessors ensure compliance with full
details contained in the competency standard.
Element and Performance Range of Variables Additional Training Topics Activity Visual
Criteria Content
01. Operate and maintain bulk This unit applies to all
dispensing systems. establishments which maintain
1.1 Bulk dispensing systems are a cellar. Operate Bulk Dispensing Disc OHT 1
correctly operated in accordance Bulk dispensing systems may systems for wine, spirits, EX HO 1a-c
with manufacturer's instructions include systems for: post-mix and beer GS OHT 2
and safety requirements.  beer HO 2a-c
 spirits
 wine
 post-mix spirits.

1.2 Temperature, carbonation and Cellar products may include Monitoring temperature, GS HO 3
pump pressure are monitored. but are not limited to: carbonation and pump Dem OHT 3
 beers (bulk and packaged) pressure PA HO 4
 wines OHT 4
 spirits HO 5a-b
 liqueurs HO 6
 aerated and mineral water
 post-mix
 juices and syrups.
1.3 Connectors, extractors and heads Cleaning connectors, GS
are cleaned hygienically. extractors and heads Dem, PA

1.4 Nitrogen and integrated systems Included in 2.2 GS

are set up safely and correctly to Dem
manufacturer's specifications. PA

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 Element and Performance Range of Variables Additional Training Topics Activity Visual
Criteria Content
1.5 Faulty products and product Identifying faulty products Dis OHT 5a-b
delivery problems are promptly Identifying faulty delivery HO 7
and accurately identified. systems. OHT 6
HO 8a-b

1.6 Faults are promptly corrected or Correcting Faults Dis OHT 7

reported to the appropriate person. Reporting Faults Dem
Pa
EXC

02. Operate and maintain beer

reticulation systems.
2.1 Beer reticulation systems are Operating the bulk beer SS OHT 8
correctly operated and cleaned in system safely as the Dem HO 9
accordance with manufacturer's manufacturer requires PA HO 10
instructions.
2.2 Safety procedures regarding Safe handling, connection HO 11
handling, connecting and storing and storage of gas HO 12a-b
of gas are strictly followed.

03. Use and maintain refrigeration

systems.
3.1 Refrigerator temperatures are Refrigeration systems may Why refrigeration systems Dis HO 13
measured accurately and include but are not limited to: are used? Dem
adjusted to comply with product  portable systems Types of refrigeration PA
requirements.  cold rooms systems GW
 cabinets Daily checklist for monitoring
 instantaneous coolers. temperatures
Re-set on/off switches for
emergencies

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 Element and Performance Range of Variables Additional Training Topics Activity Visual
Criteria Content
3.2 Refrigerator seals and catches are Looking for wear in door GW HO 14
maintained to manufacturer’s seals and catches HO 15a-c
specifications. Why it is important to monitor OHT 9
maintenance
3.3 Refrigerator vents, coils and filters Cleaning cooling Cleaning vents, coils and Dis, GW
are cleaned to manufacturer’s towers filters Dem, PA
standards.
3.4 Walk-in cool room alarms are set Cleaning the cool Setting cool-room alarms GS
and re-set when required and to room Dem
manufacturer’s standards.
3.5 Basic mechanical faults are Basic cool-room Exc OHT 10
recognised and immediately maintenance GS
repaired, or reported in Also see 3.2
accordance with enterprise
procedures.
Cleaning the ice Cleaning the filter GS
machine Cleaning the air-cooled Dem
radiator PA

04. Monitor quality of cellar

products.
What is a cellar used for Dis OHT 11
4.1 Quality of cellar products are
Identifying problems in OHT 12
regularly tested and faults
quality of cellar products
identified.
4.2 Adjustments are made within Making the adjustments for Dis
scope of individual responsibility or which you have responsibility
faults are reported to the Reporting other issues to the
appropriate person. appropriate person

4.3 Follow up action is taken to ensure Dis

Rectifying faults
faults are rectified.

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 Element and Performance Range of Variables Additional Training Topics Activity Visual
Criteria Content
4.4 Bin and keg card systems are Stock control in the cellar Dis OHT 13
used to assist in monitoring the GW OHT 14
quality of products and controlling OHT 15
stock. OHT 16
HO 16
HO 17

4.5 Cellar is kept tidy, clean and free Safe lifting methods in Cellar house-keeping: Disc OHT 17
from litter. the cellar beverages, trolleys, gas Dem HO 18a-b
cylinders etc. PA HO 19a-b

4.6 Cellar temperature is monitored. Monitoring cellar temperature Disc

Legend:
Brainstorm – B Guest Speaker – GS Project – Pro
Case Study – CS Hand Out – HO Questioning – Q
Demonstration – Dem Multimedia – MM Role Play – RP
Discussion – Dis Notes to Teacher or Trainer - NTT Research – R
Excursion – Ex Overhead Transparency – OHT Simulation – S
Group Work – GW Practical Application – PA Video – V
Presentation – Pre

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4.2 How to teach the competency standard
What skills, knowledge and
attitude do I want the trainee or
student to have?
Operating Bulk Dispensing systems for
wine, spirits, post mix and beer
Setting up safe nitrogen and integrated
systems
Monitoring temperature, carbonation and
pump pressure
Cleaning connectors, extractors and heads
Identifying faulty products
Identifying faulty delivery systems
Package for Hospitality Training – Operate cellar systems
How will I transfer the skills, knowledge and attitude to the trainee or student?
Trainer to show OHT 1 [Components of a bulk beer dispensing system].
Trainer to discuss what a bulk dispensing system consists of and give Handout 1a-c [Types of bulk
dispensing systems]
Trainer to take trainees on a field trip to a large hotel restaurant with a cellar system. While on Tour, trainees
to observe the areas on OHT 2 [Cellar products] and Handout 2a-c [Cellar products] to assist as they work
through the training package.
Trainer to give trainees Handout 3 [The gas plant] on types of gases used in bulk dispensing systems.
Trainer to go through the handout and explain the uses of each gas.
Trainer to give OHT 3 [Bulk beer dispensing equipment] and Handout 4 [Bulk beer dispensing
equipment] and OHT 4 [Beer line plumbing] and Handout 5a-b [Beer line plumbing]. Trainer to organise
visits to enable participants to see bulk dispensing systems operating.
Trainer to organise visits by equipment experts to talk about systems with emphasis on safe operations and
maintaining quality of products dispensed.
Trainer to give Handout 6 [What pressure should be used?]
Guest speaker or Trainer to discuss temperature, carbonation and monitoring pressures
Trainer to arrange demonstrations of procedures and allow participants to have hands-on practice.
Trainees to complete Activity 1 on Handout 6. This may be completed during the industry visit or at their
workplace.
Trainer or a guest speaker to demonstrate how to:
 Clean connectors hygienically
 Clean extractors hygienically
 Clean heads hygienically
Trainer to allow participants to have hands-on practice.
Trainer to give OHT 5a-b [Beer fault finding], Handout 7 [Trouble shooting] and OHT 6 [Wine making
faults], Handout 8a-b [Wine making faults] on: Troubleshooting beer and wine
 Identification of faulty products
10
What skills, knowledge and How will I transfer the skills, knowledge and attitude to the trainee or student?
attitude do I want the trainee or
student to have?
Trainer to discuss possible delivery problems
E.g. Broken cartons or containers missing items, incorrect invoices, incorrect products, poor quality product.

Correcting and reporting faults
Trainer to discuss with trainees what needs to be reported for expert assistance.
E.g. show OHT 7 [Possible post mix malfunctions].
Trainer to explain that in the event of a failure in the post mix system, four checks should be done before
ringing for maintenance
1. Water
Check the water inlet tap has not been turned off.
2. Electricity
Make sure the electricity has not been disconnected.
3. Syrups
Ensure the syrup tanks are not empty
4. CO2
Look at the regulator to make sure the gas is not empty or that it is turned on. If after you have checked
the above and it still won’t work, call the company for repairs
Trainer to arrange demonstrations of trouble-shooting procedures and allow participants to have hands-on
practice
Participants should have the opportunity to talk to real life practitioners (either visit to work site or visit to class
by expert) about practical trouble-shooting.

Operating the bulk beer system safely as
the manufacturer requires
Operating and cleaning the beer reticulation system safely as the manufacturer requires see OHT 8 [Operate
the bulk beer system safely] and Handout 9a-b [Operate the bulk beer system safely], Handout 10 [Beer
lines/cleaning and maintenance].
Trainer to organise visits by equipment experts to talk about systems with emphasis on safe operations and
maintaining quality of products dispensed.
Trainer to arrange demonstrations of procedures and allow participants to have hands-on practice.

Safe handling Trainer to give Handout 11 [Operate the gas system?].

Connection and storage of gas Trainer to arrange for trainees to observe the gas system being operated.
Trainer to give Handout 12a-b [Gas safety].
Trainer to discuss with the group the problems associated with using gases and particularly the DANGERS of

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What skills, knowledge and
attitude do I want the trainee or
student to have?
Why refrigeration systems are used
Types of refrigeration systems
Daily checklist for monitoring temperatures
Re-set, on/off switches for emergencies
Looking for wear in door seals and
catches
Why it is important to monitor maintenance
Cleaning vents, coils, filters and cooling
towers
Setting cool-room alarms
Cleaning the cool room
Basic cool-room maintenance
Package for Hospitality Training – Operate cellar systems
How will I transfer the skills, knowledge and attitude to the trainee or student?
using gases.
Trainer to discuss:
 What is a refrigeration system and why refrigerator systems are used OHT 17 and Handout 18a-b
[Storage of cellar products].
Trainer to discuss the need for constant monitoring of temperatures.
Trainer to give monitoring Handout 13 [Temperatures].
Trainer to discuss the need for accurate measurement and adjustment of refrigerator temperatures
Trainer to demonstrate how to reset on/off switches for emergencies. (Trainees to practice).
Trainer to give Handout 14 [Door seals and latches]:
 Looking for wear in door seals and catches, Trainer to give Handout 15a-c [Preventative maintenance
schedules] setting up a preventative maintenance system and show OHT 9 [Tools for maintenance].
Samples of worn and new door seals and catches should be provided so participants know what they should
be looking for and what is acceptable and not acceptable.
Trainees to work individually or in groups to develop a maintenance schedule of their own for existing or
factious refrigeration system.
Trainer to organise visits by equipment experts to talk about bulk dispensing refrigerator systems with
emphasis on safe operations and maintaining quality of products dispensed.
Trainer to arrange demonstrations of procedures and allow participants to have hands-on practice with:
 cleaning refrigerator vents
 cleaning coils
 cleaning cooling towers (with special reference to the control of legionnaire’s disease)
 cleaning filters.
Guest-speaker or Trainer to demonstrate and discuss:
 setting cool-room alarms
 cleaning the cool-room.
Show OHT 10 [Cool rooms]
12
What skills, knowledge and How will I transfer the skills, knowledge and attitude to the trainee or student?
attitude do I want the trainee or
student to have?
 Use and purpose of cool-rooms
Participants should have the opportunity to visit cool-rooms and talk to those responsible for their operation.

Cleaning the ice machine Trainer to organise visits by equipment experts to talk about Ice Dispensing Systems with emphasis on safe
Cleaning the filter operations and maintaining quality of products dispensed.
Cleaning the air-cooled radiator Trainer to arrange demonstrations of procedures and allow participants to have hands-on experience cleaning
the ice machine and maintaining the ice machine.

What is a cellar used for? Trainer to show OHT 11 [The cellar]

Testing quality of cellar products  What is a cellar and what products is it used for
Identifying problems in quality of cellar Trainer to discuss how to identify problems with quality of cellar products
products Trainer to show OHT 12 [The storage of cellar products].

Making the adjustments for which you have Trainer to arrange for trainees to obtain a position description of employees responsible for cellar operations
responsibility and to identify their roles and responsibilities and reporting lines. Facilitate discussion of what adjustments to
Reporting faults to the appropriate person product quality could or could not be made within the normal scope of responsibilities and to whom problems or
faults should be reported.

Rectifying faults Trainer to facilitate discussion on how to go about rectifying faults within a cellar storage system e.g. What are
the faults and who would fix them?

Stock control in the cellar Trainer to facilitate discussion and show overhead on OHT 13 [Factors affecting stock control procedures].
Trainer to discuss with trainees the reasons for OHT 14 [Stock control]
Trainer to explain stock and show OHT 15 [Stock rotation] and OHT 16 [Use of bin cards]
Course participants should be given the opportunity to observe a variety of stock control systems in the industry
and write them up in report format.
Trainee to practise completing a bin card system for a variety of stock items use Handout 16 [Example of bin
cards] as an example of a completed bin card and Handout 17 [Blank bin card].

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What skills, knowledge and How will I transfer the skills, knowledge and attitude to the trainee or student?
attitude do I want the trainee or
student to have?
Monitoring cellar temperature Trainer to discuss the temperature of the cellar e.g.
Generally a cool part of the establishment
Free from direct sunlight and heat
It may not be cool through air-conditioning or refrigeration but because of its location.
Should be kept at a constant cool temperature
Gas stored at no more than – 32 o C
Wine store between 15 – 17 o C.

Cellar housekeeping: beverages, trolleys, Trainer to show OHT 17 [Storage of cellar products] and Handout 18a-b [Storage of cellar products].
gas cylinders etc. Trainer to discuss the importance of safe lifting techniques.
Trainer to demonstrate safe lifting techniques.
Trainees to practice safe-lifting techniques.
Trainer to give Handout 19a-b [Cellar hygiene].
Trainer to discuss the areas listed on the handout and ask trainees to brainstorm about what would happen if
hygiene procedures were no adhered to e.g. Products go bad. Rodents and insects would damage stock.
Customers would get sick.

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4.3 Support materials
(Overhead transparencies
/Handouts)
 OHT 1

Components of bulk beer

dispensing system

Bulk dispensing system may include system

for:

A. Bulk wine system.

B. Bulk spirit system.

C. Post – mix system.

D. Bulk beer dispensing system.

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 HO 1a

Types of bulk dispensing systems

A. Bulk wines system

Wines can be dispensed in a similar manner to that of
bulk beer, using a bulk wine dispensing system.
The system uses Nitrogen or compressed air to push the
wine through stainless steel pipes and the wine is
dispensed using either a tap font or gun similar to post-
mix, gas pressures are adjusted through the regulator and
this dictates the speed at which the wine is dispensed.
The wine is cooled, if necessary using an instantaneous
cooling system to a temperature of 7 – 10o C.
The bulk wine lines require less frequent cleaning than
beer lines, however the process and chemicals used are
the same.
Bulk wines are stored in 45 and 80 litre kegs and in 15
and 20 litre bags.
B. Bulk spirit system
A bulk spirit machine delivers measure nips of alcohol
through a tower or gun similar to that of a post- mix
mounted at the bar. Food grade nitrogen or compressed
air is used to move the spirit from 20 litre plastic drums or
stainless steel canisters to the dispense point.
Many of the systems will have an electronic counters
recording the amount of spirits sold during particular time
periods.
The spirit lines are serviced bi-annually with the rest of the
system by a qualified technician, however the actual
dispense equipment should be cleaned daily similar to
that of a post-mix machine.

Package for Hospitality Training – Operate cellar systems 16

 HO 1b

Types of bulk dispensing systems

(cont’d)

Canisters are to be checked daily to ensure there is no leakage. Should leaks be present inspect the tank
disconnect ‘O’ rings for signs of wear and replace if necessary.

Remember:
Similar to beers, bulk wines and spirits are stored under
pressure and the same safety measures should be
taken when working with either of the systems.
C. Bulk beer dispensing systems
The purpose of any beer dispense system is to deliver
the beer form keg to tap in brewery fresh condition.
This can be achieved by minimising the amount of
beer in the system, avoiding hot areas preventing
contamination from outside sources and delivering the
beer into the glass at the correct temperature.
A variety of systems are in used throughout the
country from direct pull cool rooms, conventional
temperate or ice bank systems with individual beer
lines in plastic or stainless steel, python systems with
heat exchange plates chilled with water or glycol, to
combinations of the above.
The most successful systems preserve beer quality
and minimise wastage by keeping the beer
refrigerated from keg to tap, eg. Direct pull and python
based systems.
However, individual circumstances vary and new
developments occur all the time, so please consult
your brewery quality technician for appropriate advice
if you are considering a new beer system.

Package for Hospitality Training – Operate cellar systems 17

 HO 1c

Types of bulk dispensing systems

(cont’d)

D. Post-mix systems
Post-mix soft drinks are dispensed through tower or
guns mounted at the bar. Normally, the post-mix
machine is located in the cellar or under the bar.
The post-mix machine normally uses food grade CO2
to pump carbonated water and concentrated syrup
from its container to the dispense point. There are two
types of containers used for holding the concentrated
soft drink syrup, canisters and dispensable syrup-
packs. The canister is connected by a gas line and a
syrup line while the syrup-pack are connected by a
single screw on fitting.
Each of the drinks should be tested daily for
temperature, flavours and carbonation. The strength
of the syrup in the beverage should only be adjusted
by a qualified technician. The in-glass temperature
after dispensing is 5o C.
The dispenser, drip tray and nozzles should be
cleaned on a daily basis. The connections to the syrup
canister should be cleaned on a weekly basis. This is
done by soaking in soda water and scrubbing with a
small brush.

Package for Hospitality Training – Operate cellar systems 18

 OHT 2

Cellar products

The cellar is a storage and dispensing area for

beverage and ancillary products. Beverage
products that may be stored in the cellar include:

 spirits / liquors

 beers, ales and stout

 different styles of wines

- bottled wine
- cask wine.

 mineral water and soft drinks

 post-mix juices and syrups.

Package for Hospitality Training – Operate cellar systems 19

 HO 2a

Cellar products

While on tour observe the following areas and

where individual items can be found. This will
assist you as you work through this training
package:
 packaged beer
 wine storage
 fortified wine storage
 refrigeration system/s
 compressor
 beer outlet/s
 bulk beer set-up
 spirit storage
 post-mix
 maintenance area
 delivery area
 bottle shop.

Package for Hospitality Training – Operate cellar systems 20

 HO 2b

Cellar products (cont’d)

Activity

Go into the cellar and list the most popular brands in the categories outlined
below. You may wish to consult with your Trainer, your Manager or look at
the Purchasing Book to determine which products are more popular than
others

Basic spirits Liqueurs Bulk beer

1. 1. 1.

2. 2. 2.

3. 3. 3.

4. 4. 4.

Packaged beers White wine Red wine

1. 1. 1.

2. 2. 2.

3. 3. 3.

4. 4. 4.

Post - mix Mineral water Fortified wines

1. 1. 1.

2. 2. 2.

3. 3. 3.

4. 4. 4.

Package for Hospitality Training – Operate cellar systems 21

 HO 2c

Cellar products (cont’d)

Activity

Ancillary products are non beverage items either sold or used in

beverage outlets. These may include straws, coasters, cigarettes
and bar towels.

List ten ancillary items that are stored in the cellar. You may wish
to consult with your Trainer.

1. 6.

2. 7.

3. 8.

4. 9.

5. 10.

Self Check

Did you understand the activity/activities you were asked to do?

Did you allocate enough time to complete the activity/activities?

Do you have an understanding of the more popular brands of

beverages?

Do you have an understanding of which ancillary items may be

stored within the cellar?

If you have answered NO to any of the above questions, ask your

Trainer for help.

If you feel you do not fully understand an activity, repeat it.

Package for Hospitality Training – Operate cellar systems 22

 HO 3

The gas plant

Different types of gases are required to dispense different types of beverages

Available gases and their uses

Cylinder
Gas Type Description Uses Market
Colour
1. Beer gas French Grey High Purity Beer (bulk) Hotels, clubs,
carbon dioxide Cider Restaurants
with the words
Non flammable
‘Beer gas’ Colourless
stencilled on the Odourless
body 1 ½ times
heavier than air
2. Cella mix French Grey Non flammable Beer (bulk) in Hotels, Clubs,
Neck Non – toxic cellars where Restaurants
Colourless temperatures
Dark Admiralty Odourless are below 7oC.
body Not suitable for
beer stored at
ambient
temperatures,
post-mix or wine
3. Carbon French Grey Non flammable Soft drinks on Hotels, Clubs
Dioxide - Non - toxic post mix Restaurants,
Food Grade Colourless Fast Food
Outlets,
Odourless Convenience
Stores
4. Multi mix French Grey Odourless Stout Hotels and
Colourless neck (developed by Clubs
Non – toxic Guinness)
Admiralty body Non flammable

5. Nitrogen – Dark Admiralty Colourless Bulk wine, Hotels, Clubs,

Food Grade Odourless Juices Fast Food
Grey Outlets,
Non – Toxic Convenience
Non flammable Stores

Package for Hospitality Training – Operate cellar systems 23

 OHT 3

Bulk beer dispensing equipment

Package for Hospitality Training – Operate cellar systems 24

1. Gas cylinder 5. Beer line
2. Gas board (pressure reduction 6. Instantaneous cooler (chills the
and individual regulators) beer). If you are pulling beer from
a cool-room you may not have
3. Keg (can be more than one this piece of equipment.
hooked up together in a line –
‘bank’) 7. Tap (dispenses to customer)
4. Coupler (connects the keg to the 8. Gas lead
beer and gas line)

Package for Hospitality Training – Operate cellar systems 25

 HO 4

Bulk beer dispensing equipment

Gas is stored in a cylinder at approximately 6000

kPa (kilopascals are measurement of pressure).
This is a much higher pressure than in the keg. To
reduce the pressure as the gas passes from the
cylinder to the keg regulators are used which are
normally mounted on a gas board. However, each
regulator will give a reading for the pressure in each
beer line.
The two gauges mounted on top of the gas cylinder
show the pressure in the cylinder and the amount of
gas left in the bottle.

Remember
Each beer line has separate gas line &
regulator.
Recommended pressure for beer dispensing is 165
0 210 kPa each beer will be different depending on
its style and usage. Gauges should be set
individually by the cellar person.
To prevent over-carbonation, night gas is used
when beer is not being pulled through the lines for
extended periods, i.e. between hours of operation.
Night gas operates at around 70 kPa.

Package for Hospitality Training – Operate cellar systems 26

 OHT 4

Beer line plumbing

1. CO2 gas lead into keg

2. The Keg
3. The internal beer stem
4. Beer line
5. Coupling

Package for Hospitality Training – Operate cellar systems 27

 HO 5a

Beer line plumbing

The purpose of beer line plumbing is to transport

the beer from the keg to the tap under pressure.
There are two materials from which beer line
plumbing is made, plastic or stainless steel. In
some cases the beer line plumbing also doubles as
a cooling system, e.g. ‘python’ beer lines are water
chilled. This is done by an additional line of chilled
water running in the centre of a number of beer
lines and wrapped together in thick insulation. As
the beer travels to the tap is chilled to the correct
temperature.
Gas system
Gas is used extensively throughout the cellar and
bars of an establishment to:
 push beer through the lines while maintaining its
carbonation level
 carbonate and dispense soft drinks
 push any cleaning agents placed in beer lines
CO2 is absorbed into the beer under pressure when
cold. It is converted from gas to liquid form. The
liquid CO2 is converted back into gas as the beer
warms in the glass after pouring. It is this
conversion from liquid to gas that ensures that the
beer does not go flat in the glass.

Package for Hospitality Training – Operate cellar systems 28

Package for Hospitality Training – Operate cellar systems 29
 HO 5b

Beer line plumbing (cont’d)

ACTIVITY (1)

Record the pressure of each regulator, outlining the

beer type, gas type, cooling system used and the
consumption rate of this beer – high, medium or
low. What is the temperature of the cellar or cool-
room at the time of the reading?

Pressure Cooling
Beer Gas Consumption
kpa system

Package for Hospitality Training – Operate cellar systems 30

 HO 6

What pressure should be used?

The pressure required to get the beer to the tap in a

solid liquid mass depends on the maximum
temperature of the beer, either in the tapping area
or the lines
Typically, beer dispense installations are set up with
the following minimum pressures, however, other
factors such as type and length of lines, vertical lift,
ambient temperatures exposure to other heat
sources are relevant and higher pressures may be
required in various circumstances

Minimum
Tapping Area Temperature
pressure
Direct Pull Cool-
- 2 to 2o C 70 kPa
room
Remote Cool-room < 10o C 210 kPa
Cellar > 10o C 245 kPa

The pressure applied to the keg is generally

balanced by a calculated length of 4mm diameter
tap lead to achieve a flow rate of 70 – 80 ml per
second.

Package for Hospitality Training – Operate cellar systems 31

 OHT 5a

Beer fault finding

Sour beer may be caused by:

 poor housekeeping of equipment

 old beer

 beer drawn from taps & returned to keg

 poor operation of multiple tapping equipment.

Package for Hospitality Training – Operate cellar systems 32

 OHT 5b

Beer fault finding (cont’d)

Cloudy beer may be caused by:

 leaving beer in lines overnight

 aged beer

 poor housekeeping of beer lines and equipment

 badly cleaned / stored glassware

 beer drawn from taps & returned to keg.

Package for Hospitality Training – Operate cellar systems 33

 HO 7

Trouble shooting
Sometimes problems occur with the beer reticulation system. It is
important that you are able to identify the problem and organize to have
it fixed, or notify your supervisor or manager

Problem Likely causes Remedy by staff

Excessive wastage Supervisor or trainer to
 Incorrect dispensing instruct bar staff
technique

Flat beer or poor Check for leaks as

head described
Decrease pressure
 Gas leak in system Check temperature and
adjust temprite
Call service representative

Heady beer  Insufficient gas Increase pressure

pressure Change cylinder
 No gas – empty Check temperature and
adjust temprite
cylinder
Service Taps(s)
 Beer too warm
Check for pinched line or
 Faulty bar tap(s)
other obstruction
 Obstruction in beer Service taps(s)
line Check for pinched line or
 Beer drawing system other obstruction
unbalanced Call service representative

Cloudy beer  Yeast or Clean beer dispensing

bacteriological equipment
infection Ensure stock is rotated
 Aged beer properly
Increase Temperature to min
 Cool-room to cold 7.5o C

Off flavour or  Yeast or Clean beer dispensing

smell in beer bacteriological equipment
infection Renew beer lines
 Beer line permeation

Leaking keg or tap  Worn or damaged O Dismantle tap and replace

rings rings
 Use only certified O
rings

Package for Hospitality Training – Operate cellar systems 34

 OHT 6

Wine making faults

Common faults occur in wine making:

a. “Corked” wine

b. Oxidised wine

c. Volatile

d. Hydrogen sulphide

e. Mercaptan

f. Mousiness.

Package for Hospitality Training – Operate cellar systems 35

 HO 8a

Wine making faults

Wine is essentially a processed and packaged food. It is common

knowledge that any processed and packaged food can in some
way be faulty or spoiled. The reasons for this generally fall into
two categories:
1. The food was spoiled or contaminated in production
2. The food packaging has failed and has allowed the food to be
exposed to air and micro-organisms.

This is exactly what can happen to wine. Today, faulty or spoiled

wines do not occur often. This is due to modern wine making
techniques, however, because faulty wines do occur, you should
be aware of some of the basic reasons why this takes place.
(note: the procedure for handling customer complaints in regards
to faulty wine is dealt with in unit Customer Relations.)

Common faults
1. “Corked” wine
This is probably the most talked about fault and certainly the
most common. Current industry opinion is that anywhere from
three to five percent of all bottled wine has this fault. (5% is
one bottle in 20).
When a wine is corked, it is contaminated with a chemical
compound. This chemical will cause the wine to smell
“mouldy”, “dank” or like rotten wood. This smell can be more
or less intense depending on the level of contamination – it is
the cork.
The current thinking is that when the cork is being produced it
can be infected with a fungus. The fungus is killed by heating
or irradiation, however, the offending chemical flavour
remains.

Package for Hospitality Training – Operate cellar systems 36

 HO 8b

Wine making faults (cont’d)

2. Oxidised wine
With any food, exposure to excessive air will cause loss of
flavour and will make the wine eventually unfit to drink. Wine
is no exception. When a bottle of wine is opened, air
immediately comes into contact with the wine. To begin with
the flavour will actually be enhanced, but, depending on the
wine, after 10 – 12 hours loss of flavour will begin to occur.
Heat is linked closely to oxidization therefore a wine which is
heated too much during transport or storage can be oxidised.
3. Volatile
When a wine smells like nail polish remover (acetone) it is
suffering from volatile acidity (V.A.). This occurs because
oxygen has entered the wine and allowed a bacteria to grow
creating acetic acid.
Some customers may identify the smell as being like vinegar.
4. Hydrogen sulphide
Commonly known as H2S or “rotten egg gas”. This has a very
strong smell and is caused by too much heat or oxidisation
during the wine making process. This problem is very rare
these days.
5. Mercaptan
This fault will have the smell of burnt rubber and is another
one caused in winemaking through excessive heat or
oxidisation. This is also very rare in today’s world of high
technology and hygienic winemaking.
6. Mousiness (pronounced mouse-ee-ness)
This strangely named fault is quite new and to date the origin
is unknown. The smell and name are the same – “mousy”.
The wine will have the unfortunate smell of a mouse cage.
Thankfully this is rare.

Package for Hospitality Training – Operate cellar systems 37

 OHT 7

Possible post mix malfunctions

 Flat beverage (no gas)

 Thick beverage (too much syrup)

 Thin beverage (not enough syrup)

 Over aerated

 Beverage not flowing through sufficiently.

Package for Hospitality Training – Operate cellar systems 38

 OHT 8

Operate the bulk beer system safely

Basic beer dispense system

Package for Hospitality Training – Operate cellar systems 39

 HO 9a

Operate the bulk beer system safely

How to tap up beer for bar trading:

 turn gas system on, checking for leaks, adequate
cylinder contents and correct regulator pressure
 make sure beer lines are filled solid with water – no air
bubbles. (In systems operating at temperatures where
water will freeze, beer lines should be pressurised with
gas.)
 using oldest stock first, position the number of kegs
required for the day’s trade
 only tap sufficient kegs for day’s trading
 fit keg couplers to kegs, leaving handle up
 fit transfers leads if banking multiple kegs together, if
leads are not already fixed to keg couplers
 insert gas valve into side port of keg coupler. If multiple
kegs are banked, gas is applied to last keg only.
 depress keg coupler handles and allow time for the
kegs to fully pressurise – up to two minutes
 connect the main beer line or manifold drop lead to the
front or head keg
 pull beer up to the tap in the bar. Open tap unit beer
appears and then shut tap off immediately.

Package for Hospitality Training – Operate cellar systems 40

 HO 9b

Operate the bulk beer system safely

(cont’d)

 where instantaneous beer coolers are in use

(temprites), hand valves should be turned on now and
time allowed for refrigeration system to catch up
before pouring beer. Some refrigeration systems are
left on continuously.
Once refrigeration system is operational, beer is ready to
pour.

How to Tap the Keg

 ensure handle is in “closed’ position
 position keg coupler above valve so that locating lugs
align with slots in the neck of the keg
 fit coupler in keg neck and turn clockwise ¼ turn or 90o
 important: do not turn beyond limit
 connect gas line to side of the coupler
 pull out handle and depress until it locks into position
 connect beer line to top of the coupler.

Package for Hospitality Training – Operate cellar systems 41

 HO 10

Beer lines/cleaning and maintenance

Twice weekly:

 clean beer lines, couplings and manifolds

 clean beer taps, guns and service points

 replace seals and washers

 replace faulty equipment:

- always follow manufacturer’s instructions
- flush with water after using detergent
- turn off compressor motor
- leave open refrigeration valves.

Package for Hospitality Training – Operate cellar systems 42

 HO 11

Operate the gas system

How to operate the gas system safely:

 check contents gauge needle position to

ascertain whether the system has lost pressure
while turned off overnight.

 both flexible arms should be fitted to gas

cylinders at all times to avoid leaks.

 turn on one cylinder SLOWLY. Do not turn on

reserve cylinder until cylinder in use expires
and is turned off.

 check contents gauge for adequate cylinder

contents.

 check regulator gauge to correct operating

pressure.

 connect gas valve to side port of keg coupler

 always turn gas off at end of trading.

Package for Hospitality Training – Operate cellar systems 43

 HO 12a

Gas safety

About Gas Safety:

 any person entering a cellar or other confined space needs to

be aware of the hazards and correct use of gas systems.

 carbon dioxide (co2) is a potentially lethal gas which can cause

death by asphyxiation if in heavy concentration in a confined
space.

 (co2) gas is particularly dangerous as it is odourless, colourless,

and tasteless.

 (co2) gas is heavier than air. it will build up to lethal

concentrations in poorly ventilated confined spaces such as
cellars. the gas will build up from floor level.

 symptoms of exposure to dangerous (co2) concentrations are

increased or rapid breathing and increased heart rate. if these
symptoms are experienced – leave the area immediately!

 always use the ‘buddy system’ (as defined in work cover “alert”
April, 1998) when entering a cellar.

 a preventative maintenance system should be in place which

includes regular leak testing and servicing of equipment.

Detecting Gas Leaks:

 be aware of normal gas consumption in relation to the number

of kegs used. This will alert you to losses through leakage.

 to detect leaks in your gas system remove all gas leads from
kegs and turn off gas system. Observe the ‘content pressure
gauge’ – if the needle drops or creeps down, there is a leak.
Very slow leaks may be detected by marking the position of
the needle on the gauge, leaving overnight (gas off) and
checking the next morning.

Package for Hospitality Training – Operate cellar systems 44

 HO 12b

Gas safety (cont’d)

 specific leaks may be located by spraying or painting a soap

solution or leak detection solution over all joints and fittings
and watching for bubbles. Leaking gas values can easily be
detected by immersion in a glass of water. Again bubbles will
indicate a leak.

Detecting Dangerous Gas Concentrations

 electronic c02 detection devices are available from gas and

equipment suppliers. use of a detection device is
recommended.

 a continuous forced exhaust ventilation system will quickly

remove any build up of gas in a confined space. Installation of
an exhaust system is recommended.

 for any concerns regarding gas detection contact your gas

supplier or emergency services – fire brigade or ses.

Other Gas Safety Issues:

 all gas cylinders, in use or not, should be secured with chains or

other holding devices.

 when not in use, gas cylinders should be stored in a cool, well

ventilated space.

 regular settings should not exceed a maximum safe working

pressure of 400 kpa.

 pressure relief devices may be required in some provinces

(check with local authority)

 Internal cylinder pressures vary from approximately 5000 kPa

for a CO2 cylinder, to as high as 15000 kPa for a mix of
Nitrogen (N) and (CO2). It is important that the type of system
and regulator used is appropriately matched to the cylinder
pressure and the dispensing gas.

Package for Hospitality Training – Operate cellar systems 45

 HO 13

Temperatures

A daily checklist should include temperatures for all refrigerator

systems. Modern refrigerators have a built- in internal
temperature+ gauge. If this is not the case, a temperature reading
will have to be taken manually. When reading the temperature
manually in a fan-forced refrigerator, do not take the reading from
in front of the fan as this will give a false reading.

Some cool-rooms have warning lights or alarms that activate when

there is a problem with the temperature or the system:

 green – everything is functioning normally

 red – something is wrong; investigate immediately

Know where the reset and on/off switches are located, in case of
emergencies.

Temperatures for different refrigeration systems vary depending on

average temperatures and climatic conditions. Also different
products carry different recommended temperatures. For
example, English beers may be served a degree or so warmer
than Australian beers.

As a guideline, the following is a list of standard refrigeration

temperatures for different styles of refrigerators:

 instantaneous coolers 2 - 5o C

 cool-rooms 5 - 7o C

 cabinets 5 - 7o C

 water baths 2 - 5o C

Package for Hospitality Training – Operate cellar systems 46

 HO 14

Door seals and latches

Door seals and Latches become worn with excessive use. They
should be cleaned regularly and checked for any signs of wear.
Faulty door seals and latches should be replaced immediately as a
drop in temperature will result.
Check the refrigeration systems in the various outlets for temperature, quality of seals
and latches, and whether a warning system is present. Enter the information in the
table below and discuss you findings with your Trainer.

Maintenance
Location Style Temp Alarm
required

YES/NO

YES/NO

YES/NO

YES/NO

YES/NO

YES/NO

YES/NO

YES/NO

Package for Hospitality Training – Operate cellar systems 47

 HO 15a

Preventive maintenance schedules

Opportunities exist for staff to improve their value to

an organisation with regards to basic maintenance.
Staff who can develop good preventative
maintenance skills and are able to fix common
problems will be highly valued.

Preventative Maintenance
Preventative maintenance means regular checking,
cleaning and replacing parts daily, weekly or
monthly to ensure that equipment is running
effectively. This helps to reduce breakdowns and
maintenance or replacement expenses.
Preventative maintenance will be discussed for
other cellar and bar equipment later in the unit, but
first, refrigeration systems.

Preventative Maintenance Schedules

A preventative maintenance schedule for
refrigeration systems follows. Your establishment
may already have one in place. If so, make
comparisons between it and this one. Remember
that your establishment may not have all of this
equipment. Ask your Trainer for clarification.

Package for Hospitality Training – Operate cellar systems 48

 HO 15b

Preventative maintenance schedules (cont’d)

Description of Preventative
equipment How often
Maintenance steps
Compressor Check belts for tension
Weekly
Compressor Check the level of refrigerant in the sigh
gauge. If air bubbles appear during
operation, call the company for a top up Weekly
Compressor Shut down the plant and clean all external
surfaces with kerosene or another
recommended product Six – weekly
Evaporative Remove louvers from the cooling tower
spray and clean off build up of algae and mould
condensers Six-monthly
Air cooled Hose and brush down the cooling tower
condensers louvers Six-monthly
Cooling Tower If near trees, clean out any leaves storms
and high wind Weekly/after
Cool-room Wash down internal the ceiling and wall
surfaces with hot soapy water to prevent a
build up of mould and algae Monthly
Condenser coils Brush all dirt and dust from the surfaces
Monthly
Cabinets Shut down, defrost and clean Weekly

Cool-rooms, Check all seals and latches to ensure no

Cabinets, Ice cold air is escaping
Machines Monthly
Ice machine Clean the copper plate inside the chamber
to remove build up of impurities Weekly
Ice machine If it has a water filter, change it
Manufacturer’s
specifications
Ice machine Check and clean the air –cooled radiator to
the motor, ensure passage of air is not
restricted Weekly

Package for Hospitality Training – Operate cellar systems 49

 HO 15c

Preventative maintenance schedules

(cont’d)

Should you hear any unusual noises, vibrations or detect

burning smells, immediately turn of the machine and call
the contractor to investigate and rectify the fault. Any
delay could cause further damage and greater cost and
inconvenience.

Using the ‘Preventative maintenance Schedule’ as a guide, list the maintenance requirements for your
refrigeration system. Discuss with your Trainer the preventative maintenance and cleaning procedures
as per your schedule.

Description of Preventative How often

equipment maintenance steps

Package for Hospitality Training – Operate cellar systems 50

 OHT 9

Tools for maintenance

 spanners

 screwdrivers

 multi-grips

 vice

 hand tools

 workbench

 “O” rings and seals.

Continually check equipment for leaking washers,

seals and “O” rings.

Package for Hospitality Training – Operate cellar systems 51

 OHT 10

Cool – rooms

The cool-rooms chilled by fan-forced air, and its

used for:

 storage of bulk, packaged and individual

beverage items

 keep products at constant, pre set temperature

 cool products to desired temperature.

Package for Hospitality Training – Operate cellar systems 52

 OHT 11

The cellar

The cellar is a storage and dispensing area for

beverage and associated products

Products which may be stored include:

 beers, ales and stout

 spirits and liqueurs

 bottled wine

 cask wine

 mineral water

 soft drinks

 post – mix juices and syrups.

Package for Hospitality Training – Operate cellar systems 53

 OHT 12

The storage of cellar products

Things to remember when storing cellar

products:
 cellar should be kept a constant temperature
 beverages kept out of direct sunlight
 gas cylinders should be stored at temperatures
not more than 32o C
 all products stored off the ground
 wine bottles stored on their side (no dessert
wines)
 vintage ports stored on their sides, others
stored standing
 spirits stored standing
 use trolleys for moving kegs or tip on side and
roll
 cellar to be cleaned daily to prevent hygiene
problems
 cellar products checked for damage by rodents
and insects regularly
 rodents and insects eradicated.

Package for Hospitality Training – Operate cellar systems 54

 OHT 13

Factors affecting stock control

procedures

 size

 number of outlets

 security systems

 accessibility of beverage

 products to personnel

 location of cellar

 manager.

Package for Hospitality Training – Operate cellar systems 55

 OHT 14

Stock control

Why do we need to have stock control?

1. To make sure you do not run out of products.

2. To warn staff if products are not available.

3. To avoid carrying an excess of products.

4. To reconcile stocks with sales.

5. To monitor theft, breakage or spillage.

6. To assist in maintaining good rotation

procedures.

7. To maintain an overview of market trends.

Package for Hospitality Training – Operate cellar systems 56

 OHT 15

Stock rotation

WHY?

To ensure the customer has a fresh product.

HOW?

 F.I.F.O. - First In First Out

 store new stock under old stock when it arrives

 take account of date stamps and store

accordingly

 put new stock in cabinets at the rear

 use bin and keg card systems.

Package for Hospitality Training – Operate cellar systems 57

 OHT 16

Use of bin cards

A bin card can show:

 item

 minimum stock

 size of beverage item

 maximum stock

 date of issue

 current stock

 opening stock

 breakages

 which outlet received stock

 price

 supplier

 bin number.

Package for Hospitality Training – Operate cellar systems 58

 HO 16

Example of bin card

BIN CARD – JALA HOTEL, JAKARTA

Inventory item Johnny Walker, R.L. Stock No: 333

Inventory for period 12 – 06 – 02 to 12 – 07 – 02

Brought Forward: 15 x 750 ml

Date No: Unit Date No: Return

Balance
In Units Cost Out Units Units
14 – 06 30 14.50 0 0 0 0

0 0 15 – 06 5 0 40

0 0 17 – 06 5 1 36

0 0 19 – 06 6 0 30

09 – 07 30 14.60 0 0 0 60

10 – 07 10 0 70

11 – 07 5 0 65

11 – 07 0 2 67

12 – 07 7 0 60

A bin card system makes it possible to constantly monitor inventory levels,

inventory costs, and usage rates. For the system to work effectively, staff
must keep the records accurately. A wrong figure in the balance column on a
bin card will affect the final analysis. The task of finding such errors, can be
long and tedious.

Package for Hospitality Training – Operate cellar systems 59

 HO 17

Blank bin card

JALA HOTEL, JAKARTA Bin card

Inventory item Stock No:

Inventory for period to

Brought Forward:

Date No: Unit Date No: Return

Balance
In Units Cost Out Units Units

A bin card system makes it possible to constantly monitor inventory levels,

inventory costs, and usage rates. For the system to work effectively, staff
must keep the records accurately. A wrong figure in the balance column on a
bin card will affect the final analysis. The task of finding such errors can be
long and tedious.

Package for Hospitality Training – Operate cellar systems 60

 OHT 17

Storage of cellar products

Refrigeration systems

Refrigeration systems for the cellar and bar are

used for two reasons:

 keep products at a constant pre-set temperature

 cool product to a pre-set temperature.

The styles of refrigeration systems used in bars and

cellar can be categorised into four general groups:

 cool-rooms

 cabinets

 instantaneous coolers

 water baths.

Package for Hospitality Training – Operate cellar systems 61

 HO 18a

Storage of cellar products

Cool – rooms
These are normally the largest refrigerators and are used
for the storage of bulk, packaged and individual beverage
items. They are chilled by fan-forced air.

Cabinets
These are smaller refrigerators used to store items in
smaller quantities. They are normally situated in service
areas and may have glass windows for display purposes.
As with cool-rooms, cabinets are also chilled by fan-forced
air.

Instantaneous coolers
These systems are used for the cooling of dispense bulk
beer or wine at the point of service. Temperatures are set
according to the service temperature of different beverage
items. Some instantaneous coolers may have up to four
different beers running through them at once. The beer
travels through a coil and is cooled by liquid gas.
It is important to remember that the instantaneous cooler
is a specialised piece of equipment and adjustments
should only be made by a refrigeration specialist.

Package for Hospitality Training – Operate cellar systems 62

 HO 18b

Storage of cellar products (cont’d)

Water baths
Water baths or chilled water refrigeration systems are
similar to instantaneous coolers. Used for dispensing bulk
beer and wine at the correct service temperature, the
water bath uses chilled water instead of liquid gas to
extract heat from the beer.
A number of refrigeration techniques are used for
dispensing beer:
 cool rooms can be used by themselves to cool beer.
they need to be kept at a very cold temperature and
must be located close to the bar. This is called a
‘direct pull system’.
 instantaneous systems are located under the bar and
cool beer at point of service. Beer enters the system
at the base of the cooler and travels through a coil
being chilled by liquid gas.
Beer temperature may increase by 1 – 3 oC as it passes
through the beer lines. This will depend on the length of
the pull form the keg to the tap and the insulation
techniques.
A common system for bulk beer refrigeration is one that ha
both a cool room facility house the kegs and an
instantaneous cooing systems at the point of service.

Package for Hospitality Training – Operate cellar systems 63

 HO 19a

Cellar hygiene

Hygiene in all areas of the hotel is obviously very important. The

cellar is one area in which special care must be taken. The
following paragraphs are intended as an overview of the topic.
If beer reticulation equipment is not cleaned regularly, bacterial
growth will soon occur affecting beer quality. Beer liens,
extractors, taps and temprites must be cleaned regularly (weekly is
recommended), to avoid contamination of the beer.
The following cleaning guide has been produced by the S.A.
Brewing Co. Please note that extractors can be cleaned by using
beer line detergents.

To maintain and clean beer coolers and equipment

Maintenance
1. Wipe top of cooler with damp cloth at least once a week.
2. Clean and service taps, extractors and manifolds on a regular
basis.
Cleaning coolers and lines:
1. Turn off unit; leave all line valves on coolers open.
2. Never use hot or warm water with cleaning agent.
3. After cleaning out coolers and beer lines, flush through with
water.
4. Blow out water with CO2 or other means from coolers and
lines.
5. Only connect beer to taps to be used.
Coolers and taps not be used, Leave Dry.
6. When beer is connected to coolers to be used, turn on unit.
7. Never leave water in lines overnight or in coolers not being
used. Even if cooler is turned off, Leave Dry.
8. Turn coolers off when not is use. This will conserve power
used by refrigeration unit.

Package for Hospitality Training – Operate cellar systems 64

 HO 19b

Cellar hygiene (cont’d)

 floors mopped with hot, soapy water and hosed down; once per
week clean with bleach and rinse

 work benches kept clean and un-clutter

 empty boxes, kegs, bottles etc. removed

 wash basins cleaned.

Remember

- bad odours can permeate product

- sticky spills can attract insects and vermin

- good housekeeping means better safety.

Post mix Machine

Daily maintenance should be carried out on this, as the sugar in

the syrup makes things very sticky. There are instructions on the
machine to indicate how it should be done. Also the representative
from the company will service the unit every so often, and this
includes ‘brixing’ the machine, which means adjusting the syrup to
water ratio to the correct settings.

Shelves, under bar counters etc., all need regular maintenance

and should be cleaned with industrial strength cleansers to prevent
bacteria infection.

Package for Hospitality Training – Operate cellar systems 65

Section 5
Assessment
5.1 Workplace assessment issues

5.1.1 Workplace assessment

Assessment is the process of collecting evidence and making judgements on progress

towards satisfying the performance criteria set out in the competency standard. At the
appropriate point, judgement is made as to whether competence has been achieved.
Assessment identifies the achievements of the trainee rather than relating the performance of
the trainee to other trainees.

5.1.2 Competent

Ask yourself the question, “what does an employee really need to be able to do?” The
answer to this question will tell you what we mean by the word “competent”. To be competent
in a work related skill implies that the person is able to:
 perform at an acceptable level of skill
 organise the required tasks
 respond and react appropriately when things go wrong
 fulfil a role in the scheme of things at work
 transfer skills and knowledge to new situations.

When you assess this competency you must take into account all of the above issues to
reflect the real nature of work.

5.1.3 Recognition of Current Competence

An integrated national assessment principle provides for the recognition of current

competencies regardless of where they have been acquired. Assessment recognises that
individuals can achieve competence in a variety of ways:
 prior qualifications
 informal learning.

Recognition of current competence gathers evidence to assess an individual against

competency standards in order to determine whether they have achieved the required
competence for a job role or for recognition for a formal qualification. The assessment of
recognition of current competence is undertaken by industry certified workplace assessor.

5.1.4 Assessors

In workplace situations, an industry certified assessor would determine whether a worker was
competent to undertake the tasks entailed by this unit of competency. If you are certified to
assess this unit, then you may choose from the methods offered in this guide, or develop your
own to conduct assessment. Assessors must look at the evidence guides in the competency
standards before arriving at the assessment methods to use.

5.2 Underpinning skills and knowledge

5.2.1 Assessment of underpinning skills and knowledge

Evidence should include a demonstrated ability to correctly explain and apply principles and
practices in the hospitality industry.

Package for Hospitality Training – Operate cellar systems 64

Package for Hospitality Training – Operate cellar systems 65
You must now assess your trainee’s or students’ underpinning skills and knowledge. This
section must be completed before you go on to the next section. Underpinning skills and
knowledge for competency standard are to demonstrate competence, evidence of skills and
knowledge is required in cellar products as defined above and their characteristics including:
a. potential faults
b. shelf-life
c. correct handling and storage
d. potential dangers of working with gas and pressure
e. specific cellar safety requirements.

Should your trainees or students not have the underpinning skills and knowledge required,
you must ensure that you deliver this material before you progress to the next section.

This training may be delivered through a variety of activities including:

 theory/practical session
 workplace observation
 workplace training
 questioning – oral/written
 role play
 project work/case study.

5.2.2 Examples of assessment tasks

Use these tasks to determine if your trainees have the necessary underpinning skills and
knowledge. The table below can be used to record the result of each student and what further
training is needed.

Assessment tasks Yes No Further training

needed

Outline the dangers of working with gas and

pressure

Describe the features of specified cellar products

including potential faults, shelf life and storage
requirements.

5.3 Suggested assessment for Operate cellar

systems
The following pages list some of the methods that can be used to assess this competency.
The proposed assessments have been designed to address each element, performance
criteria and underpinning skills and knowledge for the competency.

Results of a successful assessment should indicate sufficient and relevant knowledge

and understanding to be able to infer competence. Therefore the trainee is assessed as
either competent / competence to be achieved. Examples of assessment results sheets
are included in Appendix 1 and 2.

Package for Hospitality Training – Operate cellar systems 66

 Evidence gathering methods

Assessment of practical demonstration in the workplace may include observation of the trainee:
 observation of:
- tapping kegs
- changing gas cylinders
- maintaining the post mix system.
 procedures for set up and end of trading
 cleaning procedures for bulk dispensing units
 preventative maintenance of equipment
 storage & handling of bulk products.

Third party/documentary evidence may include:

 Evaluations by customers or other staff.

Oral question or some form of written assessment/project would be useful to determine underpinning knowledge such as:
 product knowledge
 safety issues in the cellar
 uses for different gases

In off-the-job assessment, simulated activities could be used to allow the trainee to provide evidence of skills through practical
demonstration:
 The assessor will select a line of beverage products, i.e. wine, spirit or beer and observe you completing a stock-take. Based on the stock levels
an order for beverage items will be listed in the purchasing book. They will observe accurate stocktaking procedures, recognition of products
stored in the cellar, your ability to complete the purchasing book and order stock that is required, maintaining security.

Sample methods On-the-Job Off-the-Job

Package for Hospitality Training – Operate cellar systems 67

1. You work in the cellar of your establishment. The manager / supervisor has decided that all bar staff need to 
be aware of what happens in the cellar and has asked you to show two of your colleagues what you do and
explain how your work impacts on the work of bar service staff. He/ she also wants you to pay particular
attention to safety issues and show the procedures you follow for receiving and storing different kinds of stock.
Provide this information and demonstrate how to use the bulk dispensing, beer reticulation and refrigeration
systems. This example can also be used to assess unit THHGGA06A Receive and Store Stock.
2. A new staff member asks you about the safety procedure he / she needs to follow in the cellar. What would you  
say?
3. A bar attendant says that one of the beers on tap is coming out cloudy. What are the possible causes and
solutions?
 

Questions On-the-job Off-the-job

Questioning Should Focus On:

1. Techniques and processes
 Describe the process for cleaning connectors, extractors and heads in a bulk dispensing system.  
 Describe the process for cleaning refrigerator vents, coils and filters.
 Describe typical operating procedures for beer reticulation systems.  
 
2. Organisation and planning
 How would you organise a major delivery stock in a logical and efficient manner? 
3. Communication and others
 
 What issues might you need to report to colleagues and why?

4. Problem solving
 What would you do if a stock delivery failed to arrive and you had almost run out of this item? 
5. Health and safety
 Outline the major safety implications of working with each piece of equipment in you cellar.  

Package for Hospitality Training – Operate cellar systems 68

Appendices
 Appendix 1

Competency assessment result

Unit code: ITHHBFBS05AEA Title: Operate cellar systems

Trainee or student name:

Assessor name:

The Trainee was assessed as: Competent 

Competency to be achieved 

Feedback to trainee

Signatures

The trainee has been informed of the Signature of assessor:

assessment result and the reasons
for the decision

Date:

I have been informed of the Signature of trainee:

assessment result and the reasons
for the decision

Date:

Package for Hospitality Training – Operate cellar systems Appendix 1 - Page 1

 Appendix 2

Group trainee or student assessment record

Unit code: ITHHBFBS05AEA Title: Operate cellar systems

Group:

Assessor name:

Trainee name Competent Competency

to be
achieved

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 Appendix 3

List of overheads and handouts

Overhead Handout Title

number number
(OHT) (HO)
1 Components of bulk beer
dispensing systems
1a-c Types of bulk dispensing systems
2 2a-c Cellar products
3 The gas plant
3 4 Bulk beer dispensing equipment
4 5a-b Beer line plumbing
6 What pressure should be used?
5a-b Beer fault finding
7 Trouble shooting
6 8a-b Wine making faults
7 Possible post mix malfunctions
8 9a-b Operate the bulk beer system
safely
10 Beer lines / cleaning and
maintenance
11 Operate the gas system
12a-b Gas safety
13 Temperatures
14 Door seals and latches
15a-c Preventative maintenance
schedules
9 Tools for maintenance
10 Cool-rooms
11 The cellar
12 The storage of cellar products
Factors affecting stock control
13
procedures
14 Stock control
15 Stock rotation
16 Use of bin cards
16 Example of bin card
17 Blank bin card
17 18a-b Storage of cellar products
19a-b Cellar hygiene

Package for Hospitality Training – Operate cellar systems Appendix 3 - Page 1

 Appendix 4

Trainee or student evaluation sheet

Unit code: ITHHBFBS05AEA Title: Operate cellar systems

Agree Don’t Disagree Doesn’t

The following statements are about the competency
know apply
you have just completed. Please tick the appropriate
box.
1. There was too much in this competency to
cover without rushing.    
2. Most of the competency seemed relevant to
me.    
3. The competency was at the right level for me.
   
4. I got enough help from my trainer.
   
5. The amount of activities was sufficient.
   
6. The competency allowed me to use my own
initiative.    
7. My training was well organised.
   
8. My trainer had time to answer my questions.
   
9. I understood how I was going to be assessed.
   
10. I was given enough time to practice.
   
11. My trainer feedback was useful.
   
12. Enough equipment was available and it
worked well.    
13. The activities were too hard for me.
   

The best things about this unit were

The worst things about this unit were

The things you should change in this unit are

Package for Hospitality Training – Operate cellar systems Appendix 4 - Page 1

 Appendix 5

Hotel and Restaurant Materials

Amendment List

Unit code: ITHHBFBS05AEM

Unit title: Operate cellar systems

Example:

Amendment Version Page Line Amender Date

No number number number initials completed

1. Replace ‘garish’ into ‘garnishes’ A 34 5 WW 12 Mar. 02

Amendment Version Page Line Amender Date

No number number number initials completed

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

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 Appendix 5

Package for Hospitality Training – Operate cellar systems Appendix 5 - Page 1