Summary
One of the most common (and costly) questions operators face is:
“Should I fix this again… or replace it?”
The wrong choice leads to:
- Wasted service dollars
- Repeated downtime
- Staff frustration
- Failed inspections
- And capital spending that comes too late
This decision tree helps you use age, repair cost, and system criticality to support smart capital planning instead of reactive spending.
Step 1: Start With Machine Age
Even a well-maintained commercial dish machine has a practical service life of 10–15 years under continuous use.
Step 2: Apply the 30–50% Rule (Age vs. Repair Cost Logic)
Use this rule as a fast filter:
- If a single repair costs more than 30% of the price of a new machine → Start replacement planning
- If combined repairs within 12 months exceed 50% of replacement cost → Replacement is financially justified
This avoids pouring capital into equipment that will never return the investment.
Heater Replacement Thresholds
Heaters are one of the most expensive and failure-prone components.
Replace the Heater (Not the Machine) When:
- Machine is under 7 years old
- Tank, pump, and frame are in good condition
- No recurring electrical faults
- No recurring scale damage
Replace the Entire Machine When:
- Machine is 10+ years old
- Heater failure is combined with:
- Control board issues
- Pump failures
- Repeated scale damage
- Heater replacement plus labor exceeds $2,500–$3,500 on older units
At that point, you’re restoring one part of a failing system—not extending the machine’s true life.
Control Board Replacement Thresholds
Control boards introduce a different risk profile:
You’re not just paying for the part—you’re betting on the rest of the machine.
Control Board Repair Is Usually Justified When:
- Machine is under 6–7 years old
- Electrical system is stable
- No moisture intrusion history
- No prior control replacements
Replacement Is Smarter When:
- Machine is 8+ years old
- Moisture has damaged wiring
- Multiple sensors or relays have failed
- Board cost exceeds $1,800–$2,500
At that point, you’re stacking high-cost electronic risk on top of mechanical wear.
When Repeated Service Exceeds Total Cost of Ownership (TCO)
Repair decisions shouldn’t be made in isolation. Look at Total Cost of Ownership (TCO) over 24–36 months:
Factor in:
- Service calls
- Parts
- Downtime
- Overtime labor
- Rewash labor
- Chemical and water waste
- Emergency call premiums
Red Flag Rule:
If your annual repair spend exceeds 15–20% of replacement cost for two consecutive years → you are likely overspending on service instead of investing in reliability.
The “Fix It Again” Trap
Operators often repair too long because:
- “It passed inspection last time”
- “We already replaced the heater”
- “We’ll just get through this season”
- “Capital isn’t approved yet”
The problem is:
By the time capital is approved, the machine is already operating in failure mode, and now you’re paying for:
- Emergency rentals
- Overtime dish staff
- Lost production
- Hasty equipment choices
Quick Repair vs. Replace Decision Tree (Summary)
- Under 6 years old + isolated failure → Repair
- 7–10 years old + high-dollar component failure → Case-by-case
- 10+ years old + heater or control board failure → Replace
- Multiple major failures in one year → Replace
- Repair costs >50% of replacement → Replace
Bottom Line
A repair decision should:
- Restore performance
- Extend meaningful service life
- And reduce total operating cost
If it only delays the next failure, it’s not a repair—it’s a stopgap.
