ITM 0001 - Chapter 5 Facilities, Equipment, and Utensils PDF

Chapter 5 – Facilities, Equipment, and Utensils Learning Objectives 1. Understand the importance of properly maintaining equipment and utensils and the influence it has on food safety 2. Describe how work tasks are conducted in work centers. 3. Understand how the preparation and ser...

Chapter 5 – Facilities, Equipment, and Utensils Learning Objectives 1. Understand the importance of properly maintaining equipment and utensils and the influence it has on food safety 2. Describe how work tasks are conducted in work centers. 3. Understand how the preparation and service of food flows through retail food establishments. 4. Understand basic design requirements that apply to floor and counter mounted equipment used in retail food establishments. 5. Recognize the different types of cooking, refrigeration, preparation, and dishwashing equipment available for use in retail food establishments. 6. Describe proper installation and maintenance affect the operation of equipment used during the course of food production, holding, display and handling. 7. Explain the role of proper lighting in food production and warewashing areas. 8. Explain how proper heating, air conditioning, and ventilation affect food sanitation and employee comfort and productivity in retail food establishments. Design, Layout, and Facilities The design, layout, and facilities provided in a retail food establishment must be consistent with the types of foods being sold there. The equipment used in the various departments must be properly designed and sized to meet the production needs of the area. A layout that works well in one establishment may not necessarily be suitable for another that produces and sells different food items. Most equipment and facilities will be used for several years. Some general areas commonly found in retail food establishments are: Delivery and receiving Storage Preparation Hot-and-cold holding Display  Handling and service Warewashing, cleaning, and sanitizing Waste storage and pickup Housekeeping Toilet facilities It is important that you develop a flow diagram of your establishment’s operation in order to plan the physical facilities for each function. When planning a retail food establishment: Understand and visualize each function that will be conducted within the different departments. Determine the specific tasks employees must complete when performing the function Arrange the tasks in a way that allows a smooth and sequential flow within that department or area. Regulatory Considerations When planning facilities for retail food establishments, you must know about and comply with national, state, and local standards and codes related to: Health Safety Building Fire Zoning Environmental code standards Work Center Planning The department in a retail food establishment are commonly organized into work centers. These are areas where a group of closely related tasks are performed by an individual or individuals. The number of work centers required in a department depends on the number of functions to be performed and the volume of material to be handled. An employee should be able to complete the related tasks at the work center without moving away from it. The work center should also be large enough to do the job yet small enough to reduce travel and conserve time and effort. A properly designed work center will provide adequate facilities and space for: Efficient production Fast handling and service A pleasant environment Effective cleanup Equipment Selection It is extremely important to select the right piece of equipment for the job. Compare different pieces of equipment for a particular job and look at such features as: Design Construction Durability Ability to clean easily Size Cost Safety Overall ability to do the job Purchase equipment that will improve the quality of food, reduce labor and material costs, improve sanitation, and contribute to the bottom line of the establishment. Size and Design Design is an important feature of food equipment since the equipment used in a retail food establishment is subject to constant use and abuse. Equipment and utensils must be designed to function properly when used for their intended purposes. Equipment that sits on the floor must be: Elevated on 6-inch (15 cm) legs, or Sealed to the floor, or Mounted on centers to make it easily movable Clearance space and mobility make it easier to clean the floor under and behind the equipment. Equipment sealed to the floor will prevent the accumulation of debris and the harborage of pests. In retail food establishments, display, shelving units, display refrigeration units, and display freezer units located in the customer shopping areas do not have to be elevated or sealed to the floor. However, the floor under these units must be maintained in a clean and sanitary manner. Counter-mounted equipment (that is not easily movable) should be on 4-inch (10-cm) legs. This provides clearance between the counter top and the bottom of the equipment and makes it easier to clean under and around the equipment. The equipment may also be sealed to the counter. Major Costs Associated with the Purchase of Equipment: Purchase price Installation cost Operating costs Maintenance costs Finance charges Construction Materials The FDA Food Code and construction standards, such as those from ANSI, require food equipment and utensils to: Be smooth Be seamless Be easily cleanable Be easy to take apart Be easy to reassemble Have rounded corners and edges Materials used in the construction of utensils and food-contact surfaces of equipment must be nontoxic and not impart colors, odors, or tastes to foods. Under normal use, these materials must also be safe; durable, corrosion-resistant; and resistant to chipping, pitting and deterioration. Metals Metals are very popular materials in retail food establishments. Chromium over steel gives an easily cleanable, higher-luster finish. It is commonly used in conjunction with small appliances. Noncorrosive metals formed by the alloys of iron, nickel, and chromium may also be used in the construction of food equipment. Lead, brass, copper, cadmium, and galvanized metal can cause a chemical poisoning when they come into contact with high-acid foods (foods that have a low pH). Therefore, these materials must not be used as food contact surfaces for equipment, utensils, and containers. Stainless Steel Stainless steel is one of the most popular materials in retail food establishments. It is commonly the material of choice for food containers, counter tops, sinks, dish tables, dishwashers, and ventilation hood systems. Stainless steel has a durable, shiny surface that easily shows soil and is easy to clean and maintain. Stainless steel also resists high temperatures, rust, and stain formation. One factor that influences the cost of stainless steel is the extent of polishing desired, because polishing requires labor, materials and energy. Plastic You must be sure to buy food equipment that is made of only food-grade plastics. Select the one that works best for you based on intended use and durability. The harder, more durable plastics are easier to clean and sanitizer. Some examples of plastics used in retail food establishments are: Acrylics (used to make covers for food containers) Fiberglass (used in boxes, bus trays, and trays) Polyethylene (used in storage containers and bowls) Wood The FDA Food Code permits limited use of wood materials including hard maple or an equally hard, close-grained wood for cutting boards, cutting blocks, and baker’s tables. Wood is also approved for paddles used in pizza operations. Advantages of Wood: Light in weight Economical Disadvantages of Wood: Porous to bacteria and moisture Absorbs food odors and stains Wears easily under normal use Requires frequent maintenance and replacement Types of Equipment Cooking Equipment The most important criteria to use when selecting cooking equipment are the types and quantities of food prepared, ease of cleaning, durability, and energy conservation. The frame, door, exterior, and interior materials of cooking equipment should contribute to the durability and cleanability of the equipment. The type and thickness of insulation materials contribute to the energy efficiency of this equipment. Ovens Ovens are important pieces of equipment in the bakery and may well be used by other departments in a retail food establishment. The heat in an oven is distributed by radiation, conduction, or convection, depending on the type oven being used. A good oven’s temperature should rise to 450℉ (232℃) within 20 minutes, and proper heat circulation is important. Ovens should be able to cool quickly when a drop-in temperature is required. All ovens should be well insulated to prevent heat loss. Ovens should be in a well-ventilated area. Range Primary Department: Bakery Heat Distribution Conduction Commonly used in small operations Cooking surface on top of oven Rotisserie Primary Department: Deli Heat Distribution: Convection Used to cook and hold poultry and meats Powered by gas, electricity or wood burning Deck Primary Departments: Bakery, Deli Heat Distribution: Conduction Multiple ovens stacked on top of one another Each oven contains separate heating elements Convection Primary Departments: Bakery, C-Store Heat Distribution: Convection High-speed fan circulates heated air around food to reduce cooking time Multiple racks allow for more cooking in a smaller space Microwave Primary Department: C-Store Heat Distribution: Radiation Used for thawing, heating, and reheating foods Cooks small quantities of food quickly Other types of ovens may be used in retail food establishments. These include rotary, infrared, conveyor, and roll-in units. Each of these pieces of equipment has unique features and has been designed for special application. You should contact your equipment supplier to determine if this type of equipment is best suited to carry out the functions required in your operation. Refrigeration and Low-temperature Storage Equipment Refrigeration is an important feature of the safe transport and storage of perishable foods. Cold- holding permits us to have an ample supply of meats, poultry, fish, dairy products, fruits, and vegetables throughout the country during practically all seasons of the year. Refrigeration during transportation, combined with improved cold storage facilities., has helped to stabilize the price of perishable foods. Refrigerators and freezers are used to keep perishable foods fresh and preserve the safety and wholesomeness of potentially hazardous foods (time/temperature control for safety foods). Many foods deteriorate rapidly at room temperature. Retail food establishments can reduce spoilage, waste, and shrinkage by keeping foods at lower temperatures until they are used. Proper cooling requires removing heat from food quickly enough to prevent microbial growth. Improper cooling of potentially hazardous foods (TCS foods) is consistently identified as one of the leading contributors to foodborne illness. Bacteria grow best at temperatures between 70℉ (21℃) 𝑎𝑛𝑑 120℉ (49℃). The storage of food in shallow containers placed on slatted shelves or tray slides to permit good circulation of the chilled air is essential for both short – and long-term storage. Do not line shelves in refrigerators and freezers with sheet pans, foil, plastic, or cardboard. This decreases airflow in the storage compartment and reduces the cooling of the equipment. Store raw products under cooked and ready-to-eat foods to prevent cross contamination. The size of the refrigerator or freezer needed depends on the size of the work area and the type and amount of food to be stored in the unit. Refrigeration and low-temperature storage equipment must be adequately sized and properly installed to assure reliable and efficient operations. If your targeted food product temperature is 41℉ (5℃) or lower, you will most likely need to maintain the air temperature in the refrigeration unit at a lower temperature, such as 37℉ − 38℉ (2.8℃ − 3.3℃). Maintenance of the refrigeration equipment in the various departments in an important responsibility. These units must be cleaned on a regular basis to maintain good sanitary conditions and eliminate odors. The inside walls, floor, shelves, and other accessories of a walk- in refrigeration unit must be cleaned regularly to remove spills and debris. Don’t forget to clean the fan grates and condenser as part of your routine cleaning. Reach-in Refrigeration Reach-in Primary Departments: Bakery Deli C-Store ▪ Models range in capacity ▪ Can have multiple doors ▪ May have external thermometer attached to a sensing device inside the warmest part of the refrigeration unit Walk-in Primary Departments: Dairy Meat Seafood Deli Produce C-Store ▪ Stores large quantities of perishable foods between 32℉ (0℃) 𝑎𝑛𝑑 41℉ (5℃) ▪ Used to thaw products ▪ Can be combined with reach-in dairy/deli display cases that are located from inside the walk-in ▪ Should be located at a site that is easy to get to from the receiving and production areas ▪ Door openings may have 4-inch-wide plastic strips called strip curtains, which reduce cool air loss when the door is open. ▪ May have external thermometer attached to a sensing device placed at the warmest location in the refrigeration unit Display Primary Departments: Grocery Meat Seafood Deli  Dairy Produce C-Store ▪ Keep cold foods out of the temperature danger zone and frozen foods solidly frozen while on display ▪ Avoid stocking above the maximum load line. ▪ Avoid covering vents and return air-openings ▪ Properly control defrost cycles ▪ May be open air or have closing doors Cook-chill and Rapid-Chill Systems Cook-chill is a system in which food is: Cooked using conventional cooking methods Rapidly chilled using a chiller Stored for a limited time Reheated before service to the customer The food is typically chilled to 37℉ (4℃) in 90 minutes or less and is stored at temperatures between 33℉ (1℃) 𝑎𝑛𝑑 38℉ (3℃) for 5 days. The advantages of this system include reduction of peaks and valleys in production and readily available foods. The disadvantages of this system include the high cost of the chiller and the storage space requirements. Rapid-chill systems are designed to cool hot foods very quickly. This type of equipment can typically get a few hundred pounds of hot food through the temperature danger zone in 2 hours or less. Although this equipment is somewhat expensive, it can be very good investment for some retail food establishments that work will large masses of food or with foods that are challenging to cook quickly. Be Prepared in Case of a Power Failure: 1. Keep refrigerator doors closed 2. Monitor product temperatures 3. Discard products that are in the temperature danger zone for more than 4 hours Hot-holding Equipment Potentially hazardous food (time/temperature control for safety food) that has been cooked and is to be eaten hot must be held at 135 ℉ (57℃) or above. An important fact to remember is hot- holding equipment will not raise the temperature of foods very much. In order for hot-holding equipment to work properly, the food must be at 135℉ (57℃) or above when it is put into or onto this equipment. Hot-holding equipment uses steam, heating elements, or lightbulbs to keep foods hot. This equipment should be checked regularly to make sure it is working properly. Food temperatures must be monitored to assure that they are being maintained at 135℉ (57℃) or above. Hot- holding units must be cleaned regularly, and food should be rotated using a FIFO procedure. Other Types of Food Equipment Slicers The basic design of food slicers includes a circular knife blade and carriage that passes under the blade. Foods to be sliced are placed on the carriage and fed either automatically or by hand. Slicers can be dangerous if not used properly. The manufacturer’s instructions should always be followed, and employees should receive training on safe operation and proper cleaning of this equipment Mixers, Grinders, Choppers, Tenderizers, and Saws Mixers can also be used to shred and grind when different accessories and attachments are used. Floor model mixers have three standards attachments: (1) a paddle beater for general mixing, which can be used to mash, mix, or blend foods and ingredients; (2) a whip to incorporate air into products; and (3) a dough hook used to mix and knead dough. Mechanical tenderizers are commonly used to improve the edible quality of meat. Tenderizers cut connective tissue in meats and poultry by making incisions with stainless steel blades. The depth and the spacing of the blades and the frequency with which the meat is penetrated control the amount of tenderizing. Grinders and choppers work well with a variety of fresh foods and ingredients including meats and vegetables. Band saws are commonly used in meat and fish processing areas. Heavy-duty saws are best suited for large volume retail food establishments. These saws are designed to cut meat and bone and hold up under continuous heavy use. Counter-top and light-duty saws are commonly used in small delis, meat shops, and small establishments. This equipment is excellent when cutting boneless meats, chicken, and fish. Band saws must be durable, easily cleanable, and safe to use. Food-contact surfaces must be made of nontoxic materials that provide good sanitation qualities. Employees must be able to disassemble this equipment for easy cleaning, preferably without tools. Band saws must be properly guarded or have a “dead man” switch to protect the operator from contact with the blade. Ice Machines Ice is an important item in retail food establishments. It is used to chill beverages and preserve the freshness of fish and some produce items during display. Ice must be made from potable water and ice machines must protect the ice during production and storage. The parts of an ice machine that come into contact with the ice must be smooth, durable, easily cleanable, and constructed of nontoxic materials. These food-contact surfaces must be cleaned and sanitized regularly to prevent the growth of mold and other microorganisms. The drain line from the ice machine must be equipped with an air gap to protect the ice from contamination due to backflow. Scoops, shovels, carts, and other equipment used to dispense or transport ice must meet the design and construction criteria for food-contact surfaces. When not in use, this equipment should be stored in a manner that will protect it from contamination. Employees must never dispense ice by passing a glass or cup through the ice. This can cause glass from the container to break off and become a physical hazard in the ice. Food and beverage containers must not be stored in ice that will be used for drinking purposes. This prevents contamination of the ice your customers may consume. When scoops are stored inside an ice machine, they must be placed in a bracket mounted to a wall of the ice storage compartment. This will prevent employees to use the handle of the scoop without their hands touching the ice or the food-contact surface of the scoop. Ambient Temperature Display Equipment Many foods in retail food establishments are displayed at room temperature. These include shelf- stable products, certain types of produce, bakery items that have a low water activity (bagels, cookies, doughnuts, etc.) and bulk foods, such as candy, peanuts, and cereals. These are not considered PHF (TCS), and they can be held safely at room temperature. However, they must be protected from contamination by customers and the environment. Ambient display equipment can have both food-contact and non-food-contact surfaces. The food-contact surfaces of the equipment must be cleaned and sanitized regularly to remove contaminants. Non-food-contact surfaces must be cleaned regularly to remove spills and eliminate soil. Stock on display should be rotated using the FIFO method, and utensils should be provided so customers will not contaminate unpackaged food with their bare hands. Some produce display equipment is equipped with misters that help assure the freshness of fruits and vegetables and prevent wilting, dehydration, and shrink. These misters must be connected to a possible water supply, and the system and heads of the system must be properly cleaned and maintained to assure maximum freshness, safety, and wholesomeness of produce exposed to the mist. Live Seafood Display and Holding Tanks Fish, crustacean shellfish (crabs, lobsters, and shrimp), and molluscan shellfish (oysters, clams, and mussels in the shell) are live and perishable products that must be protected to remain safe, wholesome, and attractive to customers. The quality of the product in live seafood tanks is only as good as the water in the tank. Water quality is critical, and the key to maintaining optimum water quality is filtration. There are two different types of seafood display tanks, one for fish and one for molluscan shellfish. To operate a fish or crustacean shellfish tank, the water quality and tank maintenance are important to maintain the health of the animals, but these products are not ready-to-eat and are intended to be cooked by the consumer. To operate a live molluscan shellfish tank, additional precautions are required because the shellfish may be eaten raw. Before an operator installs and sells raw molluscan shellfish from a live tank, a variance must be acquired from the regulatory authority. Single-service and Single-use Articles Single-service articles include tableware, carryout utensils, and other items, such as bags, containers, stirrers, straws, and wrappers designed and constructed to be used only one time by only one person. After one use, the article is discarded. Single-use articles include items, such as wax paper, butcher paper, deli paper, plastic wrap, and certain types of food containers that are designed to be used once and discarded. A retail food establishment should provide single-use and single-service articles for food handlers if it does not have proper facilities for cleaning and sanitizing multi-use kitchenware and tableware. These establishments must also provide single-service articles for use by consumers. Materials used to make single-service and single-use articles must not permit the transfer of harmful substances or pass on colors, odors, or tastes to food. These materials must be safe and clean when used in retail food establishments. Warewashing Equipment Warewashing is the process used to clean and sanitize the equipment, utensils, dishes, glasses, and so on, that are used during the preparation, handling, and consumption of foods. Proper warewashing is one of the most important jobs in a retail food establishment. Warewashing areas must be well lighted and well ventilated. Noise-absorbing materials may be installed on walls and ceiling to lower noise levels in warewashing areas. Some of the items most frequently washed and sanitized in a retail food establishment are: Utensils, such as knives, forks, spoons, and tongs Kitchenware, such as pots, pans, cutting boards, slicers, grinders, and mixers Tableware, such as dishes, glasses, and eating utensils The purpose of warewashing is to clean and sanitize equipment and utensils. It consists of two phases: 1. A cleaning phase in which visible soil is removed from the surface of the item through washing and rinsing 2. A sanitizing phase in which the number of disease-causing microorganisms on a cleaned surface is reduced to safe levels. Cleaning and sanitizing operations can be performed either manually or mechanically. Most retail food establishments are manual warewashing operations to clean and sanitize equipment and utensils. Some larger establishments may use a mechanical dishwashing machine to perform these tasks. Manual Warewashing A manual warewashing area must provide adequate space to store soiled equipment and utensils. Items to be cleaned must be pre-flushed, or pre-scraped and, if necessary, pre-soaked to remove food particles and soil. A hose and nozzle or other device must be provided to pre- flush and pre-scrape food soil into a garbage container or disposal. This equipment must be located at the soiled end of the warewashing operation to avoid contaminating cleaned and sanitized equipment and utensils. Manual warewashing can also be performed using a bucket and brush, wall-mounted hose units, and spray units. The compartments of the three-compartment sink must be large enough to accommodate the largest pieces of equipment and utensils used in the retail food establishment. Supply each compartment with hot and cold potable running water. Provide drainboards or easily movable dish tables of adequate size for proper handling of soiled utensils prior to washing and for air- drying cleaned and sanitized items. Mechanical Warewashing Mechanical warewashing machines may be used by retail food establishments but are far less common than a three-compartment sink. Dishwashing machines can be used to clean and sanitize equipment and utensils that do not have electrical parts and that will fit into the machine. When using a single-tank, stationary-rack dishwashing machine, the dishes are placed on racks and washed one rack at a time with jets of water within a single tank. They are operated by opening a door, inserting a rack of dishes, closing the door, and starting the machine. A dishwashing machine must automatically dispense detergents and sanitizers. These machines must have a visual means to verify detergents and sanitizers are delivered or a visual or audible alarm to signal if the detergent and sanitizers are not delivered to the respective washing and sanitizing cycles. The machine must be large enough to accommodate the size and volume of equipment and utensils to be cleaned and sanitized. Low-temperature dishwashers are similar in design to the single-tank, stationary-rack dishwashing machine. However, they use chemicals to sanitize equipment and utensils. This allows lower water temperatures, which conserve energy. Installation Proper installation is required to assure equipment functions properly. The best design and construction will be worthless if electrical, gas, water, or drain connections are inadequate or improperly installed. The dealer who sells you equipment may or may not be responsible for its installation. Arrangements for installation will usually be specified in your purchase agreement. Following installation, employees must be trained to operate equipment correctly and safely. Maintenance and Replacement The cost of care and upkeep on a piece of equipment may determine whether or not its purchase and use are justified. Successful maintenance of equipment requires definite plans to prolong its life and maintain its usefulness. Such plans place emphasis on a few simple procedures: Keep the equipment Follow the manufacturer’s printed directions for care and operation. Post the instruction card for a piece of equipment near it Stress careful operation and maintenance schedules. Make needed repairs promptly Some valuable suggestions for the care of equipment are: Assign the care of a machine to a responsible person Check the cleanliness of machines daily Have repairs performed promptly and by a properly trained person Lighting Proper lighting in production and dishwashing areas: Increases productivity Improves workmanship Reduces eye fatigue and employee irritability Decreases accidents and waste due to employee error Shows when a surface is soiled and when it has been properly cleaned Food production and warewashing areas should be furnished with the proper amount of lighting and soft colors that reduce glare. Locate lights to eliminate shadows on work surfaces or glare and excessive brightness in the field of vision. The amount of light required in a department or area depends on the kind of work performed there. Heating, Ventilation, and Air Conditioning (HVAC) Air conditioning in retail food establishments means more than simply “cooling the air.” It includes heating, humidity control, circulation, filtering, and cooling of the air. HVAC systems must filter, warm. humidify, and circulate the air in the winter and maintain comfortable air temperature in the summer. Ventilation in food production and warewashing areas is typically provided by mechanic exhaust hood systems. These systems keep rooms free of excessive heat, steam, condensation, vapors, obnoxious odors, smoke, and fumes. The standard ventilation system used in retail food establishments consists of a hood, fan, and intake and exhaust air ducts and vents. Ventilation hood systems must be designed and constructed to prevent grease or condensation from dripping onto food, equipment, utensils, linens, or single-service and single-use articles. The capacity of the ventilation system should be based on the quantity of vapor and hot air to be removed. Hoods are usually constructed of stainless steel or a comparable material that provides a durable, smooth, and easily cleanable surface. The hood should be equipped with filters or other grease- extracting equipment to prevent drippage onto food. Filters and other grease-removal equipment must be: Easily removed for cleaning and replacement Designed to be cleaned in place Please see video lessons on YouTube 1. Module 5 – Basic Equipment and Facilities https://youtu.be/x7cKXZa4sCU 2. ServSafe Video 6 Facilities Cleaning Pest Management https://youtu.be/ONAEvIWEPsw References/Suggested Readings Successful Restaurant Design, John Wiley and Sons. New York, NY. Barbara, Regina S., and Joseph F. Furocher Design and Layout of Fodsrevice Facilities, John Wiley and Sons. Hoboken, NJ. Birchfield John C. and Raymond T. Sparrowe Food and Drug Administration and Conference for food Protection. Food Establishment Plan Review Guide. Washington, DC. Food and Drug Administration, Food Code., U.S. Public Health Service Washington, DC. Food and Nutrition Science. A Guide for Purchasing Food Service Equipment. U.S. Department pf Agriculture, Washington, DC. Principles of Food Sanitation. Norman G. Marriott, M. Wes Schilling, Robert B. Gravani. Food Hygiene and Sanitation. S. Roday Food Safety, Sanitation, and Personal Hygiene. B.C. Open Textbook Project., open.bccampus.ca Essential of Food Safety and Sanitation – David McSwane, Nancy Roberts Rue, and Richard Linton Food Safety in the Hospitality Industry. Knowles, Tim. Principles of Food Sanitation. Cristina Garcia Jaime HACCP Reference Manual, The Education Foundation of the National Restaurant Association Foodborne Pathogenic Microorganisms and Natural Toxins, Food and Drug Administration State Training Branch www.proprofs.com ServSafe Essentials ServSafe Coursebook, 7th Edition. National Restaurant Association. 2018. Pearson