Design

1
Design Layout of Foodservice Facilities
2
Overview

• This introduces the major kinds of manufactured
  foodservice equipment, discussed below under six
  functional categories
• Receiving and storage
• Pre-preparation
• Final preparation
• Service
• Warewashing
• Waste removal

3
ShelvingSelection Considerations

• Portable (on casters), freestanding (on posts),
  or wall-hung (cantilever)?
• How many tiers (shelves), usually four or five
  for bulk storage depends on size of product
  containers
• Shelving material chromed wire, epoxy wire,
  stainless steel, plastic? depends on intended
  use and budget
• Shelving design solid, louvered, wire?
  depends on intended use and budget
• Light duty, standard duty, or heavy duty
  depends on weight of items stored

4
Walk-In Coolers/FreezersSelection Considerations

• Prefabricated vs. Built-In (rare)
• Panels of steel, aluminum, or stainless steel
  depends on operator preference and budget
• Size (see Chapter 4)
• Floor design recessed in slab, on slab with
  ramps, or floorless
• Location of compressors remote outdoors is best
• Refrigeration power depends on level of use
• Interior temperatures for freezers
• Features, such as lighting, alarms, and windows

5
Reach-In Refrigerators/FreezersSelection
Considerations

• Primary cold storage capacity for the food
  facility, or is the refrigeration being used to
  augment walk-in refrigerators and freezers
• What capacities of storage are needed for
  reach-in refrigerators and freezers in the food
  production area
• One, two, or three compartments
• General storage, with shelving, or special
  products that would fit better on interior tray
  slides
• Should the refrigerator be adapted for roll-in
  carts
• What special features are required

6
Mixers (60 qt 20 qt pictured)Selection
Considerations

• Product types and batch sizes
• Demand (needed capacities)
• Mix of sizes is appropriate where batches vary
  from large (60 QT) to small (20 QT)
• Desired accessories

7
Buffalo ChopperSelection Considerations

• Types of items requiring chopping
• Quantities desired
• Generally used for large runs of chopping

8
Food Processor (Table Top)Selection
Considerations

• Batch size
• Bowl type processors are limited to small batches
• Continuous feed attachments accommodate larger
  quantities
• Types of processing and required blades

9
VCM (Vertical Cutter Mixer)Selection
Considerations

• Best for very large batch sizes
• Ideal for commissary type production

10
SlicerSelection Considerations

• Number of units required
• Diameter of blade (size of cut)
• Manual versus automatic
• Type of sharpener
• Attachments (such as food chute)

11
Standard Ovens (Under Range)Selection
Considerations (Disadvantages)

• The location under the range makes it difficult
  for the cook to see or reach into the oven.
• The ovens are poorly insulated and thus
  energy-inefficient.
• Under conditions of heavy usage, standard ovens
  require frequent maintenance and repair of door
  hinges and thermostats.
• Cleaning under and behind standard ovens is
  extremely difficult.
• The capacity of the standard oven is relatively
  small in comparison to other oven designs.

12
Convection OvensSelection Considerations

• Number, quantity, and size of items to be baked
  determine how many oven compartments are required
• Mounting on legs or casters
• Glass or solid doors
• Exterior finishes
• Sophistication of controls

13
Deck OvensSelection Considerations

• Type of product and batch sizes determines number
  of decks and height of cavities
• Steel versus brick hearth (bakers often prefer
  brick)
• Gas versus electric
• Note Use much more floor space than convection
  ovens for a given capacity

14
Rotary OvensSelection Considerations

• Products and batch sizes determine number of
  trays
• Gas versus electric
• How to ventilate
• Hard-crust breads require steam injection
• Ovens are very large best for big batches

15
Revolving Rack Oven

• Product size and batches determine capacity
  (number of racks)
• Energy (gas vs. electric)
• Steam injection for crusty breads
• Very space efficient for large batch baking or
  roasting

16
Conveyor OvensSelection Considerations

• Capacity a function of belt length, width, and
  speed in relation to required cooking times for
  products
• Sizing determined by peak demand for products
• Ovens can be stacked to double or triple
  production rates
• Do not require skilled operators once set for a
  standard product, they remain set.

17
Slow-Roasting OvensSelection Considerations

• Primarily used for roasting meats
• Number and size of compartments determined by
  type and quantity of meats to be roasted

18
Combi Steamer OvenSelection Considerations

• Compartment profile determined by pan type (12 x
  20 counter pan, sheet pan/roasting pan)
• Required capacity determined by batch size and
  frequency
• Multiple compartments can be ordered to
  accommodate different products and cooking
  requirements
• Large capacity (roll-in rack) units are available
• Gas or electric service

19
Tilting Braising Pan (Tilting Skillet)Selection
Considerations

• Capacity (determined by expected batch size)
• Gas versus electric power
• Generally best to purchase larger capacity (since
  marginal cost of greater size is low)

20
Steam Jacketed KettlesSelection Considerations

• Number of kettles and capacities of each,
  determined by recipes and batch sizes
• Stationary versus tilting
• Fully or partially jacketed
• Mounting wall, legs, pedestal, table
• Accessories draw-off, faucet, lids, mixer

21
SteamersSelection Considerations

• Typical pan size for cooking (12 x 20 counter
  pan versus 18 x 26 sheet pan) determines cavity
  width
• Batch sizes and quantities determine capacities
• Units can be stacked
• Direct steam (preferred), electric generator,
  electric elements, or gas boiler

22
BroilersSelection Considerations

• Hotel style, open top (shown), salamander, or
  conveyor
• Anticipated demand, product size, and cooking
  time determine size needed
• Gas versus electric (versus special fuel like
  wood)
• Hood requirements

23
RotisserieSelection Considerations

• Rotary or Vertical
• Capacities determined by product size, batch
  size, and cooking times
• Gas versus electric

24
FryersSelection Considerations

• Number of fryers determined by product mix (avoid
  frying fish and fries in same oil) capacities by
  batch sizes and cooking times
• Gas versus electric
• Table mounted, modular, drop-in, or free-standing
• Automatic basket lifters, solid-state controls,
  automatic loading systems
• Stainless frying chambers and/or exterior panels

25
RangesSelection Considerations

• Types open top, radial fin, griddle, hot top
  (not recommended)
• Capacities determined by demand and cooking times
• Usually gas
• Accessories include rear shelving, ovens,
  refrigerated drawers (shown), salamanders

26
GrillsSelection Considerations

• Size determined by product and demand
• Cooking plate thickness
• Cooking plate surface (e.g chrome versus steel)
• Thermostatic controls
• Table top, modular, drop-in, freestanding
• Gas versus electric

27
Bakery Equipment ProoferSelection
Considerations

• Batch size of yeast products determines size
  (single versus multiple compartments)
• Simple baking requirements can be met with a
  humidity controlled hot food box
• Complex baking requirements better served by a
  dedicated proofer

28
Bakery Equipment - Dough SheeterSelection
Considerations

• Necessary only where sheet dough products are
  produced in high quantities
• Demand determines capacity

29
Food Warmers Selection Criteria

• Tremendous variety available, from drop-in
  warmers for counter pans (shown) to large hot
  food carts and pass-through warmers
• Sizes and quantities depend on application

30
Beverage Systems - CoffeeExamples
Espresso
Portable Brewer
Urn
31
Beverage Systems - CoffeeSelection Considerations

• Urns used for large quantity batch production
• Portable coffee brewers distribute fresh coffee
  to multiple locations
• Espresso machines selected by market and menu
  considerations
• Selection of all types driven by demand and batch
  sizes.

Espresso
Portable Brewer
Urn
32
Bar Equipment

• (left to right) Bottle Refrigerator, drain board
  with glass storage, speed rail with condiment
  storage, bottle storage, ice bin with cold water

33
Bar EquipmentTypical Selection

• Ice chestan insulated storage area for ice (does
  not make ice)
• Drain boardboth a work surface and a place to
  set glasses and utensils to air-dry
• Blender stationa space designed for blenders,
  including a small sink for sanitizing utensils
• Refrigerated storage chestfor holding condiments
  and cooling bottles
• Hand sink, including soap and towel
  dispensersrequired by the health department
• Three-compartment sinkrequired by the health
  department for washing and sanitizing glassware
• Storage bins-a place to stack 20-by-20-inch
  racks of clean or dirty glasses
• Bottle rails, often called speed railsused for
  storing open bottles of the bar liquor stock
• Fruit drawera special drawer to store fruit that
  will be used in mixed

34
Ice MachinesSelection Considerations

• Capacity determined per discussion in Chapter 7
• Match production capacity to bin size
• Air versus water cooled ice maker

35
Ice DispenserSelection Considerations

• Top down, scoop, or counter (shown)
• Capacity determined by number of drinks to be
  dispensed
• Ease of loading this counter unit has an ice
  maker underneath that refills the bin

36
Dish Machines Single Tank Door Type

• Manual scraping and loading
• About 50-55 racks per hour maximum capacity
• Requires special racks and high sides for tall
  items
• Hot or sanitizing rinse
• Generally electric heated
• Straight line or corner machine

37
Dish MachineRack Conveyor, Single Tank

• Conveys racks through the machine
• Single wash tank fresh water for each rinse
  cycle
• Capacity upwards of 200 racks/hour
• Electric, gas, or steam tank heat
• Electric, gas, or steam booster heat

38
Dish MachineRack Conveyor Two Tank

• Conveys racks
• Separate wash and rinse water tanks (saving water
  compared to single tank model)
• Capacity upwards of 250-275 racks per hour
• Electric, gas, or steam tank heat
• Electric, gas, or steam booster heat

39
Carousel Dish Machine

• Like a two-tank conveyor with a continuous
  circular rack transport
• Racking system options
• Off-loading system options
• Electric, gas, or steam tank heat
• Electric, gas, or steam booster heat

40
Dish MachineFlight Type

• Dishes and trays loaded on pegs on continuous
  belt
• High capacity
• Length of loading and air drying sections
• Electric, gas, or steam tank heat
• Electric, gas, or steam booster heat

41
Dish MachinesTypical Accessories

• Blower dryer for rapid air drying of dishes and
  utensils
• Chemical sanitizing
• Vent hoods for each end of the machine
• Stainless-steel legs and frames (standard on some
  machines)
• Stainless-steel enclosure panels to cover the
  motors and plumbing
• Automatic fill
• Energy-saving features such as automatic shutoff
  after dishes (or racks) pass through the machine
• Common water, steam, and electrical connection
  points

42
Power Pot Wash SystemSelection Considerations

• Replaces manual pot sink
• Whether to incorporate disposal
• Size of sink bowls determined by pot and pan
  sizes and volumes
• Drain board lengths longer is generally better

43
DisposersSelection Considerations

• Sizing 2 HP for prep areas, 5 HP for dish
  washing
• Sink or cone size (some health departments forbid
  disposers in prep sinks)
• Control panel type
• Pre-rinse
• Covers

44
Water Recirculation System

• Built into soiled dish table and connected to
  scrapping trough
• 5 HP recommended

45
Pulper-Extractor System

• Reduced waste handling
• Reduced water consumption
• Labor simplification
• Requires high percentage of paper in garbage
  (e.g. disposable serving plates, cups, etc.)

46

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