Food Product Flow and Kitchen Design Fall 2024 PDF

Food Product Flow and Kitchen Design Chapter 4 in FOODSERVICE ORGANIZATIONS Learning Objectives Differentiate among conventional, ready prepared, commissary, and 4.1 assembly/serve foodservice operations. Describe differences in food product flow in different...

Food Product Flow and Kitchen Design Chapter 4 in FOODSERVICE ORGANIZATIONS Learning Objectives Differentiate among conventional, ready prepared, commissary, and 4.1 assembly/serve foodservice operations. Describe differences in food product flow in different foodservice 4.2 operations. Define terms such as cook-chill, cook-freeze, sous vide, centralized 4.3 service, and decentralized service. Observe a foodservice operation and draw a diagram showing the 4.4 flow of food in that operation. Food Product Flow the department that buys the food the process of preparation Food can travel along many different paths from the time it enters a food service operation until it is served to the public Food product flow : Refers to the alternative paths within foodservice operations that food and menu items may follow, initiating with receiving and ending with service to the customer. Alternative paths have been aimed primary at increasing productivity, decreasing cost or strengthening control of operationsimproving the management and oversight of processes to ensure efficiency, consistency, and quality. For example, implementing tracking systems in a factory to monitor production rates and quickly address any issues or delays ensures smoother operations and reduces errors. Type of Foodservices staff salary Faced with both increasing labor costs and a shortage of highly skilled employees, foodservice managers have been open to using new forms of foodservices with laborsaving features. buying cooked chicken New food products, available in various forms and stages of preparation, have appeared on the market in increasing numbers each year.  system where food is prepared in advance, then chilled or frozen and stored for later use. The food is typically reheated and served when needed, allowing for better scheduling of kitchen labor and more efficient use of resources. In some hospitals, meals are prepared in large batches, then chilled or frozen. When Types of Foodservices needed, these meals are reheated and served to patients, ensuring quick service while reducing the demand for on-the-spot cooking. Airlines often use ready-prepared foodservice, where meals are cooked and frozen or system where food is prepared, cooked, and served on-site, typically in the same location where it chilled before being loaded onto the plane. The flight attendants then reheat the meals will be consumed. This approach involves preparing meals from scratch using raw ingredients. before serving them to passengers. In most restaurants, chefs prepare dishes from fresh ingredients in the kitchen. Meals are Catering companies that handle large events might prepare food in advance at a cooked to order and served immediately to customers, maintaining freshness and quality. central location, then transport it to the event site. The food is reheated and served at the event, making it easier to manage large volumes of meals with consistency. In many hospitals, food is prepared in an on-site kitchen where meals are tailored to patients' Ready dietary needs and delivered directly to their rooms. Conventional This method reduces labor demands during peak service times and allows for better control over food quality and portioning. Some schools use conventional foodservice where meals are cooked on-site daily using fresh Prepared ingredients. The food is then served directly to students in the cafeteria. This method allows for high-quality, freshly prepared meals but requires a well-trained kitchen staff and can be labor-intensive. Commissary Assembly/Serve like brownies or croissant. like a cafeteria 1. Conventional / Traditional Foodservice Conventional foodservice has traditionally been used in most foodservice operations and is the most dominant type of food service operation Foods are purchased in various stages of preparation.‫ﺗﻢ اﻻﻧﺘﻬﺎء ﻣﻨﻬﺎ ﻓﻲ ﻧﻔﺲ اﻟﻤﺒﻨﻰ‬ Production, distribution, and service are completed on the same premises. Following production, foods are held hot or refrigerated, as appropriate for the menu item, and served as soon as possible. Foods prepared in the conventional foodservice may be distributed for service directly to an adjacent or nearby serving area, such as a cafeteria or dining room. Ex: Restaurants, most hospitals, small schools -Simplest flow for a conventional foodservice operation -This flow pattern is seen most often in restaurants where food is prepared to order Food product flow in a Conventional Hospital Foodservice operation  1. Conventional / Traditional Foodservice In hospitals and other healthcare facilities, food may be served on trays, using centralized or decentralized service. Centralized Conventional Decentralized Service Foodservice Service Centralized Service involves preparing and plating food in one central location (such as a kitchen), then transporting it to various service areas. Decentralized Service involves preparing food centrally, but it is portioned and plated in smaller service areas closer to where it will be consumed. 1. Centralized Service (Hospitals): Meals are prepared and plated in the central kitchen, then delivered to patient rooms on trays. 2. Decentralized Service (Hotels): Food is prepared in a central kitchen but sent to smaller service kitchens on each floor, where it is plated and served for room service. 2. Ready Prepared Foodservice Ready prepared foodservices have evolved because of increased labor costs and a critical shortage of skilled food production personnel. In ready prepared foodservices, menu items are produced and held chilled or frozen until heated for service later. A significant difference between ready prepared and conventional foodservices is that menu items are not produced for immediate service but for inventory and subsequent withdrawal stored Ex: Aircrafts , some hospital…  2. Ready Prepared Foodservice Menu items are Partially cooked, rapidly chilled, held in chilled storage, and reheated just prior to service. Many hospitals using the cook-chill technology will plate the food for patients in a chilled state. Reheated just prior to service using either special carts or convection or microwave ovens. Cook-Chill French term for Under vacuum classified as ready prepared because it involves chilling or freezing menu items https://www.allrecipes.com/article/what-sous- vide/ https://www.seriouseats.com/food-lab- Sous Vide Cook-Freeze Menu items are partially cooked, rapidly frozen, held in complete-guide-to-sous-vide-steak freezer storage, and reheated just prior to service. 2. Ready Prepared Foodservice Use of any of the ready prepared cooking methods requires particular care to assure that time and temperature controls are in place and are monitored during the production of the foods to control the growth of pathogens. Challenges in ready prepared foodservices are retention of microbial, nutritional and sensory quality of food; the critical control points for cooling and reheating are extremely important in this type of foodservice. Accurate forecasting and accurate production schedule are needed to maintain the quality of food and avoid prolonged holding especially in the chilled state Food product flow in a Ready Prepared Foodservice Operation using Bulk reheating reheating many foods all at once Food product flow in a Ready Prepared Foodservice Operation in hospital or aircraft with centralized tray assembly and decentralized reheating store or facility that provides supplies, typically food and other essentials, to a specific group of centralized kitchen or food production facility that prepares large people, such as members of the military, employees of an organization, or inmates in a prison. It can quantities of food to be distributed to various locations, such as also refer to the place where these items are prepared or distributed. schools, hospitals, correctional facilities, or airlines. The food is usually 3. Commissary Foodservice cooked, portioned, and then either delivered hot or packaged and sent to the receiving sites, where it may be reheated and served. schools within the district. The meals are then sent to each school, where they are reheated and served to students. airline may use a commissary to prepare and package meals for Centralized procurement and production facilities flights, which are then delivered to planes before departure. prisons or jails, ensuring consistent food quality and cost control across locations. Foods generally purchased in large quantities Distribution of prepared menu items to serve remote areas for final preparation A foodservice system in which food production and services are separated, food is prepared at one location and then transported for service at another location Menu items are often delivered hot or cold/hold and served. Ex: Caterings, central kitchen in multiple chain restaurants 3. Commissary Foodservice Commissary Foodservice: centralized procurement and production facilities with distribution of prepared menu items to several remote areas for final preparation and service. Centralized production facility and then different “satellite serving units”. Ex: large restaurant chains that have several branches in the country, might operate one big centralized kitchen and several small kitchens This help reduce the duplication of production, labor and equipment than if production was done at each service center. Space required in each service center can be minimized 3. Commissary Foodservice Food purchased typically have received little or no processing. Food generally are purchased in large quantities and held after delivery under appropriate environmental conditions in dry, refrigerated or frozen storage walk in storages, big freezers and refrigerators Most menu items in commissary foodservices are processed completely in the central facility. Because of the large quantities produced, the equipment for preprocessing and production often is different from that used in conventional foodservices. Food product flow in a Commissary foodservice operation using cook-chill and reheating food on site after transportation  4. Assembly/Serve Foodservice The development of assembly/serve foodservices—called convenience-food foodservices or the minimal cooking concept—occurred primarily because of the market availability of foods that are ready to serve or require minimum cooking. Another factor has been the chronic shortage of skilled personnel in food production and the increasing cost of labor. Menu items are purchased prepared and require minimal cooking before service Little if any preprocessing is done onsite, and production is very limited. Fresh, frozen, and dried items like shredded lettuce, sliced carrots, beef stew, proportioned roast beef, and lasagna are purchased in an assembly/serve foodservice. pre-prepared and pre-portioned food items are purchased from suppliers and then assembled, heated, and served to customers on-site. This approach minimizes the need for extensive kitchen facilities and culinary staff since the cooking and preparation are done elsewhere. Pre-cooked meals are bought from a vendor, then reheated and assembled in the hospital kitchen before being served to patients. Meals are pre-cooked by a catering company, then delivered to the airline, where they are reheated and served on the flight. Some fast-food outlets may use pre-prepared components (like frozen patties or pre-cut vegetables) that are assembled and cooked quickly before being served to customers. 4. Assembly/Serve Foodservice Market Bulk Forms of Preportioned big plates Food small packed foods Preplated foods already plated they just need go heat it 4. Assembly/Serve Foodservice Market forms of food Bulk Pre-portioned Pre-plated Review: Types of Foodservices Ready Conventional Prepared Commissary Assembly/Serve Planning Kitchen Design and Layout Planning a kitchen and arranging work areas to minimize operating costs and maximize productivity is an important activity for a foodservice manager. Planning a kitchen involves both design and layout components and consideration of flow principles. 1. Design focuses on the overall space planning and includes defining the size, shape, style/decoration of a space. 2. Layout focuses on the detailed arrangement of equipment, floor space and counter space. 3. Flow, the movement of product or people in an operation, should be an important consideration in the planning process.  Product Flow refers to the movement of food through various stages of preparation, storage, and service in a foodservice operation. It ensures that food moves smoothly from receiving to storage, preparation, cooking, and finally serving, minimizing Kitchen Flow cross-contamination and delays. In a restaurant kitchen, raw ingredients are received at the back door, stored in coolers or dry storage, moved to preparation areas, cooked, and then plated for service in the dining area. Traffic Flow refers to the movement of people (staff, customers, or both) within a foodservice environment. Efficient traffic flow minimizes bottlenecks, reduces accidents, and ensures that staff can move freely without interfering with each other's tasks. In a cafeteria, customers enter, pick up trays, move along the serving line, and exit after paying at the register. Staff move in designated areas behind the serving line, ensuring they don't cross paths with customers, thus maintaining a smooth operation. Product Flow Kitchen Flow Traffic Flow Components of a Foodservice Design Lighting Materals Heating & Air Conditioning Lighting Lighting decisions, which focus on what to light and how to light it, can be the most important environmental decisions made. A restaurant’s lighting system can account for approximately one-third of its energy costs. So the lighting decisions have cost implications for a foodservice operation.  Types of Lighting Direct Lighting Lighting Indirect Lighting Direct Light is light that shines straight from a source, such as a bulb, directly onto an object or surface without any obstruction or Indirect Light is light that has been diffused or reflected diffusion. It creates sharp shadows and bright illumination in the before reaching an object or surface. It creates a softer, more lit area. even illumination without harsh shadows. Overhead Task Lighting in a Kitchen: A row of bright LED lights - **Ambient Lighting in a Dining Area:** In a restaurant, light installed directly above the cooking or preparation stations fixtures might be aimed at the ceiling or walls, allowing the provides direct light, ensuring chefs can see clearly when light to reflect softly throughout the dining area. This creates chopping vegetables or cooking on the stove. a comfortable and cozy atmosphere without harsh shadows. Spotlights in a Restaurant Display Area: A spotlight shining - **Under-cabinet Lighting:** In a kitchen, under-cabinet directly on a dessert display case highlights the food items, lights that reflect off the countertops can provide indirect making them more visually appealing to customers. light, illuminating the workspace evenly without causing glare or direct shadows.  Negative Air Pressure occurs when the air pressure inside a space is lower than the air pressure outside. This causes air to flow into the space from outside. In kitchens, negative air pressure helps to prevent odors, smoke, and contaminants from escaping into adjacent areas. In a commercial kitchen, the exhaust hood creates negative air pressure by drawing out smoke and steam from cooking, ensuring that these elements are vented outside rather than spreading to the dining area. HVAC Systems Positive Air Pressure occurs when the air pressure inside a space is higher than outside, causing air to flow out of the space. This is used to keep contaminants from entering a clean or sensitive area. In a food storage area or cleanroom where food is prepared, positive air pressure is maintained to prevent dust, pests, or outside contaminants from entering, thereby protecting the food from contamination. The quality of the air in the workspace is controlled by the heating, ventilation, and air-conditioning (HVAC) system. Control key environmental factors such as room temperature, humidity, air movement, air quality… HVAC systems works with air in a variety of ways to achieve a comfortable work environment Ex: Negative air pressure and Positive air pressure Materials Pl al as et t M ic s Eq Materials rs u oo ip m Fl en t  Principles of Motion Economy Principles of motion economy relate to the design of work methods, of the workplace, and of tools and equipment. These principles specify that movement should be: Simultaneous Symmetrical Natural Rhythmic Habitual Principles of Motion economy Principles of motion economy that pertain to the human body Use of both hands, coordination of hands and eyes and continue motion – are aimed specifically at reducing the efforts and energy required to do a job The Principles of Motion Economy focus on minimizing unnecessary movements to improve efficiency. Key ideas include: 1. Use both hands simultaneously. 2. Minimize motions by reducing unnecessary steps. 3. Use shortest distances for movements. 4. Leverage tools or machines for heavy work. 5. Organize workstations for easy access to tools and materials. These principles save time and reduce worker fatigue. Key Terms DO NOT MEMO Assembly/serve Menu items are Charrette Collaborative planning purchased prepared and require minimal session. cooking before service. Commissary foodservice Centralized Blueprint Shows specifically the layout procurement and production facilities with of the planned space; the mechanical, distribution of prepared menu items to electrical, and plumbing details; and the several remote areas for final preparation proposed finish materials. and service. Bubble diagram Defines spaces in the Construction documents Collection of planned kitchen and the relationship of blueprints and elevation drawings for a these spaces to each other. construction project. Centralized service Plates or trays are Conventional foodservice Foods are assembled in area close to production. purchased in different stages of preparation for an individual operation, and production, distribution, and service are completed on the same premises.  DO NOT MEMO Key Terms Cook-chill Method in which menu Decentralized service Food is items are partially cooked, rapidly transported in bulk to a location chilled, held in chilled storage, and separate from production and reheated just prior to service. plates or trays of food are Cook-freeze Method in which menu assembled in that location. items are partially cooked, rapidly Design Defining the size, shape, frozen, held in freezer storage, and style, and decoration of a space. reheated just prior to service. Direct lighting Lighting aimed at a Correlated color temperature certain place. (CCT) A measure of the coolness (red, orange) to warmness (blue-white) Flow Movement of product or people appearance of a light; measured in through an operation. kelvins (K). Key Terms DO NOT MEMO Food product flow Alternative paths Layout Refers to the detailed within foodservice operations that arrangement of the equipment, floor food and menu items may follow, space, and counter space. beginning with receiving and ending Lumen Amount of light generated when with service to the customer. 1 footcandle of light shines from a source. Foot-candle Measurement of Power factor (PF) A measure of how illumination equal to 1 lumen of light on 1 efficiently a light source uses power. square foot of space. Gauge The weight of the material per square foot. Indirect lighting Lighting shining over a space rather than at a certain place. Key Terms DO NOT MEMO Program States the goals for the project, Schematic design Includes the gives an overview of the occupants of the preliminary plans for the project, space planned space, presents a projected drawings, proposed materials, electrical timeline for the project, proposes and mechanical issues, and projected costs. allocation of space to the desired units/activities within the planned space, Sous vide A process of sealing raw, fresh and details guidelines to be followed in the food items in plastic pouches to allow actual design phase. chilled storage and then cooking in boiling water prior to service. Ready prepared foodservice Menu items are produced and held chilled or Specification book Provides frozen until heated for serving. specifications and often cut sheets for all of the equipment planned for the space. Key Terms DO NOT MEMO Ventilation The circulation of fresh air in a space. Work design A program of continuing effort to increase the effectiveness of work systems.