Equipment by Functional Areas

1
Equipment by Functional Areas
Optional Side Trip

• Chapter 5
• Equipment by Functional Areas

2
Chapter 5 Objectives

• Identify
• Functional areas or the locations where a
  specific task or group of similar tasks occurs
• Space requirements
• Equipment needs
• Energy and water requirements
• Facility environmental concerns

3
Functional Areas
4
Receiving

• As a Functional Area . . .
• The first step in the flow of food
• The first control point
• The first spot to certify that products are
• In good condition
• At appropriate temperature
• Delivered as ordered

5
Receiving

• Equipment Needs
• 2-wheeled hand truck and/or 4-wheeled platform
  hand truck
• Utility carts
• Table/desk for paperwork
• Scales
• Thermometers
• Fly fan

6
Receiving

• Things to Think About
• Activities include
• Inspection of incoming food and supply items
• Acceptance or rejection of goods
• Door thresholds
• Low enough to allow hand trucks and carts to roll
  over them easily

7
Receiving

• Electrical panels
• Should not be located here
• Convenience electrical outlets
• Must be located here
• Light level
• Recommend 50 foot-candles

8
Storage

• Equipment Needed
• Shelving Materials
• Stainless Steel
• Chrome Plated
• Zinc Plated
• Epoxy Coated
• Polymer (plastic)
• Aluminum

9
Storage

• Equipment Needed
• Shelving Materials
• Stainless Steel
• Most expensive
• Excellent for use in high-humidity areas
• Most durable finish
• Chemical resistant
• Will not rust or corrode
• Will clean easily

10
Storage

• Equipment Needed
• Shelving Materials
• Chrome Plated
• Bright metallic finish
• Limited corrosion and rust protection
• More durable than zinc plating
• Should not be used in high-humidity areas, such
  as walk-ins and dish rooms

11
Storage

• Equipment Needed
• Shelving Materials
• Zinc Plated
• Bright metallic finish
• Limited corrosion and rust protection
• Most cost-effective plating
• Should not be used in high-humidity areas, such
  as walk-ins and dish rooms
• Use for dry storage, not chemicals

12
Storage

• Equipment Needed
• Shelving Materials
• Epoxy Coated
• Should be placed on plated shelves
• Good for use in high-humidity areas
• Usually carries manufacturers extended warranty
  against corrosion and rust

13
Storage

• Equipment Needed
• Shelving Materials
• Polymer (plastic)
• Will not rust or corrode
• Excellent for use in high-humidity areas
• Will clean easily
• Available in many weight-bearing capacities
• Chemical-resistant

14
Storage

• Equipment Needed
• Shelving Materials
• Aluminum
• Lightweight
• Inexpensive
• Finish will oxidize and rub off on stored
  products
• Not chemical-resistant

15
Storage

• Equipment Needed
• Shelving Materials
• Never use the following
• Galvanized or painted galvanized shelving
• Wood
• Difficult to clean and sanitize
• Will damage easily (splinters)
• Cannot be adjusted
• Will rot where it meets the floor
• Not accepted by health inspectors

16
Storage

• Equipment Needed
• Shelving Construction
• Uprights (posts) the important thing to
  remember is how the shelf is attached to the post
• Set-Screw
• Nut Bolt
• Post Clips

17
Storage

• Equipment Needed
• Shelves
• Wire
• Slatted (Louvered)
• Solid

18
Storage

• Equipment Needed
• Shelving Options and Accessories
• Explore the Possibilities
• Caster, can racks, bin markers, shelf dividers,
  pan racks, dunnage racks, and pallets
• Keep in Mind
• You are buying a storage system
• Maximize your storage space
• Chemicals, detergents, and soaps must be stored
  separately from food and paper goods

19
Soap/Chemical and Janitor Supply Storage

• Equipment Needed
• Other Equipment Considerations
• Soap and chemical shelving
• Washer/Dryer (optional)
• Laundry counter with sink
• Mop sink

20
Soap/Chemical and Janitor Supply Storage

• Soap and Chemical Shelving
• Cleanable
• 6 off floor minimum
• Chemical- roof or non-corrosive
• Solid shelves
• Mop rack needed in this room

21
Soap/Chemical and Janitor Supply Storage

• Electrical
• At least one outlet in each storage room
• No electrical panels here (electrical code
  violation)
• Recommended light level
• Minimum 30 foot-candles
• Up to 50 foot-candles in high activity areas

22
Soap/Chemical and Janitor Supply Storage

• Mechanical
• Provide heating and ventilation only
• 2 to 3 air changes per hour

23
Dry Storage

• As the Second Functional Area . . .
• Food and supplies are moved from receiving to
  dry, refrigerator, and freezer storage
• Dry storage and chemical storage must have all
  contents stored separately
• Food must never be mixed in a storage area with
  chemicals or cleaners

24
Dry Storage

• Equipment Needs
• Shelving system
• Dunnage racks
• Can storage rack (optional)
• Utility carts

25
Dry Storage

• Equipment Selection
• Shelving will impact on
• Air circulation
• Pest prevention
• Stock rotation
• Storage shelving
• Approximately 74 tall
• 21 deep shelves are ideal
• Dunnage platforms should be at least 6 off
  floor

26
Dry Storage

• Equipment Selection
• Spacing of shelves
• Four shelves in all
• The bottom shelf should be 6 off the floor
• Next two spaced at 26
• The top shelf at 74 above the floor

27
Dry Storage

• Electrical
• No electrical panels in this area (electrical
  code violation)
• At least one electrical outlet
• Recommended light level - 30 foot-candles
• Light fixtures should not extend below 8 inches
  of ceiling
• A light switch should be located in the room

28
Dry Storage

• Other Considerations
• Heating and air conditioning should be available
  in this area with 3-4 air changes/hour
• Do not place hot water heater in this area
• Install a sprinkler system for extra protection
• Environmental Conditions
• Area should be clean, dry, well-ventilated, and
  temperature-controlled
• Temperature should be between 50F - 70F

29
Refrigerated Storage

• Equipment Needed
• Walk-in cooler
• Walk-in freezer
• Cooler/freezer shelving
• Cooler/freezer dunnage racks
• Mobile angle rack (optional)

30
Refrigerated Storage

• Walk-in coolers and freezers are best
• Suggested height 8 6
• Shelving
• Approximately 60 high
• 4 shelves spaced at 18
• Bottom shelf 6 off floor

31
Refrigerated Storage

• Aisles
• Large enough for hand trucks and carts
• 36 minimum, 42 - 48 desirable
• Amount of Refrigerated Space Required
• Allow 1 sq. ft. of shelf space for each student
  meal
• Divide equally between the cooler and the freezer
• Be generous with the space allotted

32
Refrigerated Storage

• Other considerations
• Size of doors should be 36 minimum
• Floors
• Easy to clean
• Non-slip
• Level with outside floor
• Ceilings should be light-colored to reflect light

33
Refrigerated Storage

• Electrical
• Provide
• Disconnect switches as required by Code
• Lighting from front to back of refrigeration
  units
• Light switch outside of unit or in a vapor-tight
  box inside unit
• Light level at 30 foot-candles

34
Refrigerated Storage

• Mechanical
• Compressors, defroster, fans, etc. are typically
  provided with the unit
• Plumbing
• Provide a floor drain
• Locate condensing unit
• outside of building

35
Preparation/Hot Food Production

• As a Functional Area . . .
• Hot food production
• Key functional area in the conventional
  foodservice system
• Selection of type of equipment is affected by
• Menu
• Labor availability and skill
• Serving schedule

36
Preparation/Hot Food Production

• Equipment Needs
• Preparation
• Bakers table with portable bins
• Disposer
• Drinking fountain
• Food processor
• Hand sinks
• Heater/proofer cabinet
• Meat sink

37
Preparation/Hot Food Production

• Other Equipment Needs
• Preparation
• Mixer
• Portable carts
• Pot/pan shelving units
• Preparation/work tables
• Slicer
• Vegetable sink (2-compartment)

38
Preparation/Hot Food Production

• Other Equipment Needs
• Cooking
• Combination oven/steamer
• Convection oven
• Convection steamer
• Cooks sinks
• Cooling racks
• Exhaust hood
• Fryer (optional)
• fFyer filter (desirable)
• Range
• Trunnion kettles (batch cooking)

39
Preparation/Hot Food Production

• Mixer
• Range from 5-quart tabletop to 140-quart floor
  models, indicating bowl size
• Agitators flat beaters, dough arms, wire whips,
  pastry knife
• Optional equipment vegetable slicer, bowl
  splash cover, bowl extension attachment, bowl
  truck, bowl scraper, chopper/grinder, dicer,
  colander, stop and start controls, and
  programmable controls

40
Preparation/Hot Food Production

• Vertical Cutter Mixer (VCM)
• VCM consists of conical mixing bowl with motor
  mounted at bottom
• Removable sleeve with cutting blades mounted on
  motor shaft which projects from bottom of bowl
• Sized from 10-quart countertop model to 130-quart
  floor model

41
Preparation/Hot Food Production

• Tilting Braising Pan Workhorse
• A one-piece stainless steel pan with vertical
  side walls, a front pouring lip, and hinged
  stainless steel cover
• Uses
• Brown or braise stew meats, ground beef
• Fry chicken, fish
• Sauté or steam vegetables, stir fry
• Cook soups, stews, sauces
• Back-up grills, steamers, kettles

42
Preparation/Hot Food Production

• Steam Jacketed Kettle
• Cylindrical in shape with a rounded bottom, a
  second cylinder is placed on the outside to allow
  steam to circulate between the two
• Available in direct steam or self-contained
  electric or gas with stationary or tilt option
• Uses
• For boiling, stewing simmering, braising,
  holding, and reheating
• Examples
• Soups, stews, sauces, gravies, pasta, rice,
  puddings, pie fillings, vegetables, cereals, meat
  roasts, poultry, shrimp, lobster, tea

43
Preparation/Hot Food Production

• Convection Steamer
• Pressureless steamer available with
  self-generating gas or electric steam coil
  generators and direct steam models
• Each compartment capacity is equated to the
  number of 12X20X2 deep pans it will hold

44
Preparation/Hot Food Production

• Convection Steamer
• Requires a water supply
• Uses
• Steam cooking, defrosting, and reheating
• Examples
• Vegetables, rice, pasta, eggs, poultry, seafood,
  meats, prepared foods, frozen entrees, hot dogs,
  potatoes

45
Preparation/Hot Food Production

• Pressure/Pressureless Steamer
• Offers the flexibility to operate in a pressure
  (5-5 psi) steam or a pressureless steam mode
• Requires a water supply
• Uses
• Steam cooking, defrosting, and reheating
• Examples
• Vegetables, rice, pasta, eggs, poultry, seafood,
  meats, prepared foods, frozen entrees, hot dogs,
  potatoes

46
Preparation/Hot Food Production

• Combination Oven Steamer
• Offers a single cooking chamber with ability to
  cook in three cooking modes, which include hot
  air mode (convection oven), a steam mode
  (convection pressureless steamer), and a
  combination of both modes
• Available in gas or electric models
• Requires a water supply

47
Preparation/Hot Food Production

• Combination Oven Steamer
• Uses
• Roast, steam, bake, poach, blanche, grill,
  defrost, cook-and-hold, and reheat
• Examples
• Vegetables, poultry, seafood, meats,
• Frozen entrees, muffins, breads, pizza, prepared
  foods

48
Preparation/Hot Food Production

• Convection Oven
• Offers a cooking chamber with a fan to circulate
  hot air
• Available in gas and electric models
• Uses
• Bake, roast, slow roast and hold, and reheat
• Examples
• Breads, cookies, cakes, pies, meats, poultry,
  seafood, frozen entrees, pizza, potatoes, grilled
  cheese sandwiches, macaroni and cheese

49
Preparation/Hot Food Production

• Equipment Selection
• Base on menu, but keep as multi-purpose and
  simple as possible
• Specify back covers for equipment if back is to
  be visible
• Stainless steel is usually less expensive in the
  long run
• Provide soap and hand towel dispensers at each
  hand sink

50
Preparation/Hot Food Production

• Equipment Selection
• Pot and pan storage racks should be mobile
• In baking area
• Provide a bakers table with backsplashes and
  mobile ingredient bins for ease of transport from
  storage area
• Area should be convenient to a water source
• Provide mobile proofing cabinet, mixer(s), and
  oven(s)

51
Preparation/Hot Food Production

• Equipment Selection
• Provide parking space adjacent to each work area
  for mobile carts used to transport food from
  storage areas
• Provide a clock in this area
• Locate cooking equipment in a central location
  to enhance cleaning and efficiency

52
Preparation/Hot Food Production

• Electrical
• Requirements should be coordinated
• with equipment specifications
• Verify voltage, amperage, and type of connections
  required
• Electrical devices mounted near floor should be
  weatherproof and hard piped several inches off
  the floor for ease of cleaning

53
Preparation/Hot Food Production

• Electrical
• Recommended light level in the kitchen area is 75
  foot-candles
• Light fixtures should be lensed and gasketed to
  prevent moisture from damaging fixture
• Emergency lighting should be provided in this
  area to meet the requirements of the Life Safety
  Code
• Connect hood fire suppression system to building
  fire alarm system

54
Preparation/Hot Food Production

• Mechanical for Prep Area
• HVAC system should be part of system that serves
  cooking and serving areas
• Should supply a minimum cooling load of 48
  BTU/square foot
• Unit will provide the balance of make-up air
  needed to replace the air exhausted by the
  exhaust hood

55
Preparation/Hot Food Production

• Mechanical for Cooking Area
• HVAC system should be part of system that serves
  prep and serving areas
• Minimum cooling load of 100 BTU/square foot with
  room temperature of 80F
• All air supplied to the cooking area will be
  exhausted through the kitchen hood
• Hood should be U.L. listed and designed in
  accordance with National Fire Protection
  Association 96
• Hood should overhang all equipment by 9

56
Preparation/Hot Food Production

• Plumbing
• Provide hand wash sink in prep area
• Stainless steel with electric eye or foot pedal
  operation to eliminate hand contact with faucet
  handles
• Supply all prep sinks with wrist blades to reduce
  food contact with faucet handles

57
Preparation/Hot Food Production

• Plumbing
• Provide garbage grinder in drain of prep sinks
  (if approved by local plumbing codes)
• Pipe all floor drains and waste outlets from
  cooking equipment to a central grease interceptor
• Provide a master gas shut-off valve

58
Preparation/Cold Food Production

• As a Functional Area . . .
• A variety of activities take place, from washing
  produce for preparation to slicing, chopping,
  mixing, and plating

59
Preparation/Cold Food Production

• Equipment Needs
• Cooling units
• Refrigerator
• Freezer
• Blast chiller
• Mixer
• Slicer
• Cutter/Mixer

60
Preparation/Cold Food Production

• Blast Chiller
• Designed to rapidly cool food
• An essential component of HACCP system
• Product brought below 41F in 90-120 minutes or
  less
• Capacity needs (determined in pounds per load)
  equal the number of persons the chiller can serve
  for three meals per day

61
Preparation/Cold Food Production

• Ice Machine
• Ice is considered a food and must be handled as a
  food
• Rated according to the amount of ice produced in
  a 24-hour period
• Consider the storage bin plus the count of ice
  produced during the peak period total ice
  available
• Requires 20 psi water pressure

62
Preparation/Holding

• Equipment Needs
• Cabinets
• Heated
• Refrigerated
• Holding Cabinet (warming or heater/proofer
  cabinets)
• Function is to hold prepared food hot for service
  at a set temperature
• Unheated cabinets are used for holding and
  transporting large quantities of prepared foods
  not requiring holding at a set temperature

63
Preparation/Holding

• Holding Cabinet (continued)
• Mobile or stationary
• Reach-in or pass-thru
• Roll-in or roll-thru
• Aluminum or glass doors
• Pass-thru holding cabinets hold food between the
  kitchen and serving area
• Locate holding cabinets near prep and serving
  counters for efficiency
• Consider half-size doors to cut down on heat and
  cold air losses when doors are opened

64
Preparation/Holding

• Electrical
• Electrical devices are floor level,
  weatherproofed, and installed for ease of
  cleaning
• Recommended light level of 50 foot-candles
• Mechanical
• HVAC should be part of system that serves cooking
  and serving
• Should supply a minimum of 48 BTU/sq. ft.

65
Warewashing

• As a Functional Area
• The functional area of warewashing is important.
  It is here that soiled dishes, glasses, flatware,
  trays, pots, and pans are cleaned and sanitized.

66
Warewashing/Pots and Pans

• Equipment Needs
• A garbage disposal with a pre-rinse spray is
  useful at the soiled end of operation
• A three-compartment sink is needed and a
  four-compartment sink is desirable if space
  allows
• The sanitizing compartment must be large enough
  to submerge the largest pot/pan used in facility
• Hot water booster to maintain 180ºF minimum
• Chemical injector
• Drainboards provided at each end of pot and pan
  sinks, as wide as the widest sink compartment

67
Warewashing/Pots and Pans

• Location of Area
• Locate near dishwasher so that pots and pans can
  be run through dishwasher for sanitizing
• To avoid cross-contamination, do not locate
  soiled area near a clean area

68
Warewashing/Pots and Pans

• Electrical
• Electrical devices located at floor level should
  be weatherproofed and easy to clean around
• Recommended light level of 50 foot-candles
• Plumbing
• Faucets should have 3/4 supplies
• Sink compartment drains should be lever-handle
  style

69
Warewashing/Pots and Pans

• Mechanical
• HVAC system should be part of the system serving
  cooking and serving
• Based on a minimum cooling load of 48 BTU/sq. ft.
• Unit should provide balance of make-up air to
  replace air exhausted by kitchen exhaust hood

70
Warewashing/Dish and Tray

• Equipment Needs
• A soak sink in the scraping area for soaking
  flatware before washing is useful
• In larger schools a scraping trough connected to
  a disposal is more efficient
• Soiled dish table large enough to accommodate
  trays and dishes while pre-rinsing
• Pre-rinse area
• Should have an overhead spray and disposer and be
  near soiled dish table to avoid unnecessary steps

71
Warewashing/ Dish and Tray

• Equipment Needs
• The washer requires sanitizing water temperatures
  of 180ºF minimum (need booster heater)
• Automatic conveyor dishwasher, the clean dish
  table should be at least 7 long to handle a
  minimum of 4 dish racks
• Provide open space of 20 under clean dish table
  for parking rack dollies

72
Warewashing/Dish and Tray

• Electrical
• Verify location and requirements of power to sink
  heaters with plumbing consultant
• Recommended light level of 50 foot-candles
• Light fixtures should be lensed and gasketed

73
Warewashing/Dish and Tray

• Mechanical
• Exhaust hoods
• Install at entrance and exit to washer to vent
  heat and steam
• Exhaust rate of 15 to 25 air changes/hour
• System should be separate from building HVAC
  system
• Make-up air unit and exhaust fan should be wired
  to run when the dishwasher is running

74
Warewashing/Dish and Tray

• Plumbing
• Provide booster heaters capable of a 60ºF rise
  in temperature (120-180ºF) for all warewashing
  equipment
• Provide an immersion heater in pot sink to
  maintain
• 180ºF water temperature

75
Miscellaneous

• Waste Disposal
• Equipment Needs
• Garbage disposers
• Pulpers and extractor systems
• Trash compactors

76
Miscellaneous

• Waste Disposal
• Equipment Needs
• Garbage disposers
• Primary function is to grind food waste and mix
  with water
• Waste is then piped to sewer
• Specified by horsepower ranging from 1/2 to 5

77
Miscellaneous

• Waste Disposal
• Equipment Needs
• Pulpers and extractor systems
• Water and waste mixed together
• Ground into small particles
• Piped to extractor
• Water reused in grinding process and solids are
  conveyed to a conventional trash container
• Recommended when garbage disposers are against
  municipal ordinances

78
Miscellaneous

• Waste Disposal
• Equipment Needs
• Trash compactors
• Mechanical device designed to compress waste
  materials so that the volume is greatly reduced

79
Miscellaneous

• Waste Disposal
• Establish location for a grease disposal
  container
• Equip dumpster pad with water supply and drain
  for clean-up
• Provide an air curtain to outside entrances in
  vicinity of dumpster for insect control
• Do not connect garbage disposals with septic tank
  systems

80
Miscellaneous

• Can Washing and Drying
• The can drying rack should be 12 above the floor
  to allow for air circulation
• Rack should be non-ferrous to avoid rusting
• Provide area with hot and cold water supply and a
  drain for clean-up
• A hand sink should be nearby

81
Miscellaneous

• Toilets and Lockers
• Toilet areas
• The toilet areas should have toilets, lavatories,
  soap dispensers, towel dispensers, and mirrors
• Employee locker area
• Lockers 72 high by approximately 15 wide with
  provisions for locks or padlocks
• A bench and coat rack provided here or outside
  managers office

82
Miscellaneous

• Toilets and Lockers
• Equipment and space requirements must comply with
  the Americans with Disabilities Act
• Provide convenience receptacles in toilet and
  locker area

83
Miscellaneous

• Office(s)
• Equipment Needed
• Desk, chairs, bookcases, locking file cabinets,
  computer table or desk with printer stand and
  typewriter stand
• Consider
• Space and wiring for computer
• Plenty of electrical receptacles for computer and
  other office equipment