QUANTITY FOOD PRODUCTION
QUANTITY FOOD
PRODUCTION
EQUIPMENT
A. Equipment
required for mass/volume feeding
B. Heat and cold
generating equipment
C. Care and
maintenance of this equipment
D. Modern
developments in equipment manufacture
A.
Equipment
required for mass/volume feeding
Volume Feeding equipments/Industrial kitchen
appliances/Bulk kitchen Equipments are normally used in big kitchens such as in
hospitals and railway caterings.. The quantity of food cooked is huge in these
kitchens. Since industrial kitchen appliances cater to quantity, they are
preferred. Just like the normal kitchen, industrial kitchen has the same stuff
with a few accessories more. But the difference is that the domestic appliances
are just enough for a small number, but an industrial kitchen appliance caters
to a large number.
Freezers or refrigerators
An industrial kitchen requires huge freezers to
store food. Sometime, even walk in freezers are required to keep food. The
quantity cooked in large, therefore huge freezers or refrigerators are
essential to store ingredients as well as food. A cold beverage making
equipment is required for soft drinks.
Stoves
A stove is an industrial kitchen appliance used for
cooking. Usually high-end stoves are used in industrial kitchen appliances.
Coffee & Espresso Makers
These appliances help to cater to the huge demand
for coffee. Coffee makers are used to brew coffee without having to actually
boil water in a separate container.
Dishwashers
The dishwashers must be huge and capable of
withstanding the huge volumes of utensils and cutlery cleaned each day.
Fryers
Fryers are required to make deep fried snacks. They
must be energy efficient. Use of automated frying systems as a part of
industrial kitchen appliance is highly beneficial.
Grills, Broilers & Griddles
These form an integral part of industrial kitchen
appliances. They are used to cook food quickly such as pieces of meat.
Storage
Food has to be stored in appropriate containers.
Food boxes are available. Also, steam tables are required to hold
pans and sliced onions, tomatoes and cheese.
Professional cutlery, utensils
These include knives that are required for slicing
and carving and blenders. Kitchen utensils have to be bought depending on the
use. The metal and shapes of the utensils are important factors while choosing
them as industrial kitchen appliance.
Ovens, Ranges & Toasters
These are primarily used to bake and make pizzas.
Depending on the use choose the various models of microwave ovens. Microwave
ovens used as an industrial kitchen appliance have a comprehensive range of
cooking programs. There are various other ovens that helping in baking and
roasting.
Sinks & Faucets
Huge stainless steel sinks are required. Depending
on the need these sinks have to be chosen. Heavy duty faucets are also part of
industrial kitchen appliances. There are a few models that have the facility of
dispensing liquid soap.
Slicers & Dicers
These are usually used in food preparation. One
such use is to cut vegetables and fruits for salads.
Industrial kitchen appliances require huge space
and investment. Depending on the space and the budget, one can invest in these
essential industrial kitchen appliances.
B.
Heat
and cold generating equipment
Heat Generating
Equipment:
Braising Pans
The braising pan has almost as many names as it does uses. It is perhaps
the most versatile piece of commercial cooking equipment available today.
The braising pan is also known as a tilting skillet, fry pan, and
braiser. It can braise, boil, simmer, griddle cook, fry, steam, thaw, poach,
blanch, heat canned foods, act as a proof box or oven, and store hot bakery products.
This flexibility is a great asset in the commercial kitchen, where labor
and floor space are usually a primary concern and where a menu item can be
prepared entirely in this pan. Food operations can realize a 50% or greater
labor savings over conventional top or stock pot methods of cooking with the
braising pan. This is largely due to reduced cleaning requirements. The value
of a braising pan is higher in new kitchens where its flexibility allows it to
substitute for a multitude of other kitchen cookware.
The pan can be tilted a few degrees to drain fat away from food as it
cooks, such as in griddling or braising meats. Boiling about an inch of water
in the bottom of a covered braising pan can be used to steam food held on
special perforated pans or racks. Proofing is performed in a similar manner by
using hot water instead of steam
Broilers
There are 5 different types of broilers available to the foodservice
operator.
They are:
Under-fired Over-fired Salamander Cheesemelter Conveyor
Broilers provide an alternative means of cooking flavorful, nourishing
and healthful foods. Broilers are used to cook a wide variety of foods, by a
process that usually takes from 3 to 6 minutes. Steak, poultry, seafood,
hamburgers, pizza, and ethnic dishes are among the primary products normally
prepared with broilers.
Some types of broilers are used specifically to "finish off"
items like toasted breads, cheese sauces, and hot sandwiches. Depending on the
type of broiler, these food items may be cooked in metal pans, glass
casseroles, or directly on the surface of broiler grates or conveyor belts.
In the 1950s, only about 10% of the nation’s food service establishments
featured a broiler. Today, one third are equipped with broilers.
Broiler Cooking Process
Broilers use radiant energy to cook food. This is the kind of energy
used by the sun as it heats the earth. Commercial broilers use electric or gas
heat sources located either above or below the broiler cooking surface. These
heat sources cook the food directly or indirectly by way of a radiant heating
element. Some common materials used as radiants include pumice, ceramic, and
metal bars.
The delicious smoky flavor characteristic of broiled foods is a result
of juices dripping down onto the radiant or open flame of the broiler and
either igniting and/or evaporating.
Different control methods are used with different broiler types to
regulate cooking times and temperatures. Conveyor broilers have belt speed and
temperature controls, while "over fired" broilers and
"charbroilers" use high-medium-low temperature settings or adjustable
grids.
Broiler Performance
Cooking with a broiler is a relatively imprecise cooking process when
compared to other types of cooking. Food quality and consistency depend the
distance between the food product and the radiant heat elements. Cooking will
occur more rapidly when the grids containing the food product are raised closer
to the heat elements.
Periodic cleaning is very important to food quality. Charred meat that
sticks to the grids or grills can burn, transferring a bitter taste to the next
food product placed in the broiler. Also, radiant heat elements may become
coated with charred food and burnt grease. This insulates the elements and
inhibits the radiant heat transfer to the food. When this occurs, the chef must
either increase the temperature or leave the food in the broiler longer – both
of which will change the consistency of the food preparation.
So, while one fuel may be less expensive in a BTU to BTU comparison, the
best choice in cooking equipment is the one which minimizes total operating
costs, not just energy costs. Features that reduce labor costs or result in
higher food product yield will nearly always outweigh any energy
considerations. Make sure that you include all of these factors in any
equipment evaluation. Let's take a closer look at the energy-use issues,
remembering that comparisons should be made on the basis of similar equipment
where only the energy input is being changed.
Electric broilers are generally considered to be more efficient, so they
add less heat to the kitchen which ultimately must be removed by the cooling
system.
In addition, electric units require less maintenance and less
ventilation. Gas or propane broilers are generally considered to have the
advantage of using a less expensive fuel.
Broiler Components
A broiler is a relatively simple piece of equipment. The cabinet or
housing can vary in size from a small shelf mounted or counter-top unit to a
large freestanding arrangement. Some counter-top and freestanding units are
stackable or can be mounted below or above a cabinet or oven base. The inside
cooking compartment has one or more grids, sometimes called grills. Food is
placed directly on the grids or in a pan sitting on the grid. Grids have
adjustable height settings and many can slide out to make it easy to load and
unload food items. Many models have grids specially designed to drain grease
away from the heating elements and into a collection pan. These are V-shaped grids
installed at a slight downward angle. Radiant heat elements, also known as
radiants, can be powered by electricity, gas, wood or charcoal. They heat up to
a temperature high enough to induce heat transfer by radiation. Some radiants
are made of ceramic material that holds up well under high temperature and is
particularly suited to the extreme high temperature application of infrared
units.
Technology Types
New Technologies
Manufacturers of broilers continuously strive to improve food
preparation efficiency, shorten preheat times, and reduce excess heat into the
kitchen. Roller broilers are just one example of the newer technologies
becoming available. Also, new infrared broilers have made significant
improvements in these areas as well.
Back to top
Efficiency
Saving Money
The efficiency of broilers varies according to type of broiler used, the
method of temperature control, and the type of energy used. Electric broilers
are generally the most efficient, requiring less energy to preheat, less energy
to maintain idling temperatures, and less energy input during full-load cooking
conditions than comparable gas units.
Broilers are among the largest heat producers in today’s commercial
kitchens. Gas broilers radiate more heat than electric models due to their
relative inefficiency. This adds to ventilation requirements as well as kitchen
cooling costs.
Broiler energy consumptions may be optimized by following a few simple
rules:
·
Follow the manufacturer’s recommended
preheat instructions. Preheating a broiler at an excessively high temperature
wastes energy and could alter the quality and taste of the product. Also,
preheating for an extended period of time wastes energy.
·
Load the broiler to maximum capacity to
gain maximum efficiency. In addition, grates should be kept free of carbonized
grease that hinders heat transfer, lowers cooking efficiency, and mars food
quality.
·
Do not increase temperature during
"rush hours" to increase production. Energy consumption will increase
and the excessive temperature could destroy the quality of the product.
While operating all broiler sections may make sense during peak cooking
times, turn off all unneeded sections when less cooking capacity is required.
In addition, it is not necessary to have the entire broiler on at full power
even during peak periods. For example, turn one section to full heat for rare
meats, and another section to a lower setting for well-done meats. This saves
energy and money while also improving cooking consistency.
Use infrared broilers whenever possible. Infrared broilers may be turned
off when not in use and then quickly reheated when needed.
If the broiler is gas-fired, keep burner parts clean and flames properly
adjusted. A poorly adjusted flame will waste gas and may also deposit soot and
carbon on food products. Preventative maintenance should be completed according
to a routine schedule
Fryers
Fryers are extremely popular kitchen appliances and are used in about
85% of food service establishments. They are designed to cook chicken, fish,
breaded vegetables, specialized pastries, French-fried potatoes and other
foods.
The cooking medium for all fryers is hot oil, also known as shortening,
frying compound or fat. The quality of the final food product largely depends
on the quality of the oil. Oil is expensive, ranging from 30 to 75 cents per
pound (a fryer’s capacity can range from 28 to 110 pounds), and so should be
filtered often to prolong its life.
Categories:
Fryers are available in two main categories: conventional open fryers
and pressure fryers. In a survey of 3,700 eating and dining establishments in
the U.S., the National Association of Food Equipment Manufacturers found that
commercial food service facilities owned an estimated 792,000 fryers – 59%
deep-fat floor models, 27% deep-fat counter models, and 14% pressure fryers.
This study excluded institutional, recreational and retail food service
facilities, which would push the figure up to an estimated 1.4 million units.
Types:
Open, deep fat fryers – This most common type of fryer comes
in a variety of sizes,ranging from a counter top model to a large, stand-alone
unit containing multiple frypots.
Electric vs. Gas
Electric fryers preheat in 6 to 7 min. while gas fryers take 12 to 15
min. to reach full operating temperature. Note: Preheat
is directly proportionate to recovery.
Many factors are considered when selecting fryers, including cost,
productivity, and ease of operation, as well as whether to use electricity or
gas. Energy accounts for only three to five percent of a food service
establishment’s total costs. So the best choice in cooking equipment is the one
that minimizes total operating costs, not just energy costs. Features that
reduce labor costs or result in higher food product yield will almost always
outweigh any energy considerations, even if one fuel is less expensive when
compared BTU to BTU.
Heat Source
Electric units have heating elements submerged in the bottom of the
frypot. These are fixed in position or hinged to the main structure of the
fryer. Hinged units can be lifted out of the frypot for easy cleaning. They can
be high watt density (calrod) or low watt density (firebar). The low watt
density units are more efficient.
Gas units have burners outside the frypot. Some more advanced units have
fire tubes that extend through the frypot and transfer more heat to the oil.
These fire tubes often contain baffles to improve heat transfer and reduce the
amount of heat wasted by escaping up the flue.
Cold Zone
Most fryers have a cold zone, which is a small portion of the frypot
bottom extending below the heat source. When particles of food, batter and
breading escape from the basket, they sink to the bottom and collect in the
cold zone, where they stop cooking. This prevents them from burning and
degrading the oil, which lengthens the life of the oil. This design also
creates a natural convective flow of oil throughout the frypot; cooler oil
continuously recirculates with hot oil. Allowing the oil to cool in this manner
reduces oil breakdown as well.
Efficiency
Here are a few common-sense operating tips to save money with a fryer:
·
Turn the fryer off or down to an idling
temperature during slack periods when the unit is not in use.
·
Operate the fryer at the proper
temperature – 325° to 350°F. Excessive temperatures (over 400°F) waste energy
and often result in improperly cooked food and premature oil breakdown.
·
Do not load the fryer baskets beyond
the manufacturer’s recommended capacity. This is usually one-half to two-thirds
full. Overloading results in poor food quality.
·
Check fat levels frequently. Low fat
levels can cause premature oil breakdown.
·
Drain and strain the oil frequently.
This saves oil and preserves food quality.
·
Keep the units clean ad properly
maintained.
Griddles
There are 3 different types of griddles available to the foodservice
operator.
Flat Double-sided Vacuum
The griddle is the workhorse of the fast food industry. Nearly every
commercial cooking operation uses griddles of some type. A griddle is simply a
flat metal plate which cooks food by conducting heat directly from the griddle
surface to the food product. A thin layer of cooking oil or grease from the
cooked item usually separates the food from the griddle surface to keep the
food from sticking. Griddles are used to cook a variety of foods including:
bacon, eggs, chicken, hamburgers and steak. Some also like to use the hot griddle
surface to heat food in a small pan, like melting butter.
Some griddles are equipped with a platen placed a few inches above the
griddle surface to provide additional cooking from above. This add-on cooks the
top surface of the food by exposing it to radiant heat energy, cooking the food
faster and sealing in the juices for improved taste and reduced shrinkage.
Operation
Griddles can operate between 200° and 550°F, however, cooking
temperatures normally fall between 225° and 375°F. Most units reach their
thermostatically controlled cooking temperature in 15 to 30 minutes.
Griddles are usually turned on at the beginning of the cooking day and
left on all day. This arrangement wastes significant energy when the unit is
only used a small part of the time. This practice is common because griddles
take a relatively long time to preheat; it can be impractical to turn off the
unit when its not being used. In addition, food service operators like to have
the griddle cooking capacity in reserve and so they will rarely turn it off
until the end of the cooking period.
Performance
Griddle surfaces often develop hot spots and cold spots. Hot spots
usually occur near the heat source while cold zones occur in areas on the
griddle surface farthest from the heat source. Clearly, food cooks faster in
hot zones and may be difficult to control because of the higher heat. Some
griddles develop a cold zone around the perimeter, about two inches wide, which
while useless for cooking can be used to keep cooked food warm.
An experienced chef knows where the hot and cold zones are and can
adjust the cooking approach accordingly. Most griddle operators, especially in
fast food restaurants, are not this experienced, and, instead of adjusting
cooking times to account for the hot zones and cold zones, they cook everything
for the same amount of time. This results in inconsistent quality – some food
is under-cooked while some is over-cooked..
Maintenance
Griddle surfaces should be cleaned regularly. A clean griddle surface
offers the most uniform distribution of heat across the griddle surface and
operates more efficiently. Plus, a clean griddle keeps the bitter taste of
charred food out of the final food product.
The griddle operator should:
·
Scrape excess food and fat particles from
the surface with a flexible spatula, grill brick or other device after each
cooking load.
·
Clean and wipe out the grease troughs,
remove any stuck-on food and clean the surface with a soft cloth, rubbing with
the grain of the metal while the surface is still warm. This should be done at
least once a day and more often if the cooking load is heavy. The platen on a
two-sided griddle can often be much harder to clean. Some models have stainless
steel platens which makes cleaning easy. Other designs apply a special coating
to the platen surface, like Teflon, to prevent food from sticking. Still other
models use disposable, non-stick paper to prevent sticking.
Electric vs. Gas
There are many factors to consider when selecting a griddle: first cost,
food preparation productivity, ease of operation and heat generation in the
kitchen, as well as the energy source used, electricity or gas. Energy only
accounts for 3 to 5 percent of a food service establishment's total costs.
While one fuel may be less expensive in a BTU to BTU comparison, the best
choice in cooking equipment is the one which minimizes total operating costs,
not just energy costs. Features that reduce labor costs or result in higher
food-product yield will nearly always outweigh any energy considerations. Make
sure that you include all of these factors in any equipment evaluation.
Let’s take a closer look at the energy-use issues remembering that
comparisons should be made on the basis of similar equipment where only the
energy input is being changed.
Electric griddles generally offer these benefits:
More uniform temperature across the surface of the griddle. This uniform
temperature distribution makes them easier to operate and produces consistent
food quality. Thinner griddle plates that use less energy to preheat and
preheat in about half the time. More efficient operation, that means less heat
loss into the kitchen and therefore reduced kitchen cooling costs, and reduced
maintenance.
Types
There are essentially two types of griddles, single-sided and
double-sided. Single-sided griddles cook food on the bottom only. Double-sided
griddles cook food on both sides simultaneously. A griddle can be part of a
range top, installed in combination with an oven unit or part of a service
counter drop-in unit.
Double Sided Griddle
Components
Griddles come in a wide variety of sizes and may be freestanding or
incorporated into a range body with ovens below. Generally, the griddle surface
is divided into 12-inch sections, each with its own heating unit and control
mechanism. This design lets different sections operate at different
temperatures, allowing the chef to cook different kinds of food at the same
time. Griddles normally have a metal splash guard surrounding all but the front
of the cooking surface. The splash guard prevents food from sliding off and minimizes
grease splatter.
Griddle burners or heating elements normally heat only one section of
the cooking surface. Gas griddles have slotted vents for each burner for the
intake of combustion air. All griddles have at least one thermostat dial that
controls the cooking temperature. Some griddles have surface temperature
indicator lights, which are typically located on the control panel.
A grease trough, usually running along each side of the griddle plate,
drains grease and residual food particles, depositing these wastes into a
collecting pan. Grease troughs may also be located on the front or back of the
griddle. Some griddles have a pitched griddle plate that tilts to allow grease
to run-off. These units usually produce less smoke while cooking.
The cooking surface of a single-sided griddle is called a plate and its
design will usually drive the performance of the griddle. High quality plates
distribute heat uniformly across the griddle. The most common griddle plate is
made of flat steel or cast iron and ranges in thickness from one-half to one
inch.
Griddle surfaces are usually smooth and flat. However, some types of
griddles have ribbed or grooved surfaces. Grooved surfaces are designed to
emboss food with charred grid marks, characteristic of broiled and grilled
foods. Also, they allow the fat to run off and away from the product.
Ribbed surfaces cook somewhat slower than flat surfaces because only the
parts of the food in direct contact with the edges of the raised grooves are
immediately exposed to full heat. Manufacturers usually install a grooved
surface on a single section of the griddle surface only, while the remaining
sections are equipped for the total direct-contact cooking of a flat plate.
Energy Performance
Single-sided electric griddles normally consume 3 to 25 kW of power. The
average preheat time can be anywhere from 7 to 20 minutes, depending on the
plate configuration and BTU input. Energy consumption for gas single-sided
griddles normally approaches 20,000 to 30,000 BTUs per 12-inch section, and
preheat times vary from 15 to 23 minutes. Again, these figures depend on plate
configuration and BTU input. A low energy input figure generally implies slow
pre-heat and recovery time. Typical kW consumption for the electric
double-sided griddle ranges from 21 to 35 kW, with a preheat interval of about
18 minutes. Typical ratings for gas powered double-sided griddles range from
90,000 to 140,000 BTUs, with preheat times of roughly 18 to 23 minutes.
Technology Types (Resource)
New Technologies
One of the newer
electric technologies available today is the vacuum griddle. With this unit,
the griddle surface is heated by steam under a vacuum chamber and electric
elements. This produces a more uniform surface temperature and brings the
griddle surface up to cooking temperature very quickly, saving money, rejecting
less heat to the kitchen, and producing a more consistent food product. It has
the unique feature of holding plate temperature uniformity to within 1°F of
anywhere on the plate.
This technology has fast recovery and uses only 1/2 of the energy
conventional griddles use.
Efficiency
Heat Loss:
Griddles are among the largest energy consumers in the food service
industry and energy efficient operation is an important way of reducing their operating
costs. Most of a griddle’s operating costs result from heat loss from its six
sides: the bottom, the top, and all four edges of the cooking surface. These
losses are amplified because of the relatively small quantities of food cooked
on a large surface most of the day.
Heat lost from a griddle warms the kitchen making it uncomfortable for
workers unless the cooling system removes the excess heat. These losses can add
significantly to overall cooling costs, which is an important factor favoring
electric griddles over gas units. Even in un-air conditioned kitchens, where
cooling costs are not an issue, worker productivity and morale suffer as the
room temperatures rises, which ultimately increases total costs through lower
worker performance and increased turnover.
Many higher quality griddles are designed for enhanced energy
efficiency. Manufacturers increase griddle efficiency with newly developed
griddle plate surfacing. These improved surfaces restrict the griddle’s
normally excessive radiation of energy. In full-load cooking tests, griddles
achieve anywhere from 31% to 71% efficiency. Griddle inefficiency is most
evident in light-load cooking operations, where efficiency generally ranges
from 13% to 50%.
It takes 77 BTUs to heat a pound of ground beef from 40°F Fahrenheit to
140°F. Interestingly, 196 BTUs are required to heat the same pound of beef from
0°F to 140°F. Therefore, simply thawing food before cooking can have a major
impact on energy savings.
Tips on Use
Here are simple tips on how to save money when using a griddle:
·
Heat only the griddle sections
necessary for a task.
·
Pre-heat only until the griddle surface
has achieved the correct cooking temperature.
·
Set the temperature for each section no
higher than that required to cook the food.
·
Turn the griddle down or off during
slow production times.
·
Use pre-cooked foods and avoid frozen
products where possible.
·
Use a cover while cooking where it will
not adversely affect the cooking process.
·
Scrape the cooking surface between
production intervals. Cleaning some types of griddle surfaces requires special
tools. Consult the manufacturer or owner’s manual for details.
·
Clean the griddle frequently, and
always re-season the griddle afterwards.
·
Inspect each section of the griddle
periodically, searching for hot or cold spots.
·
On gas units, make sure each gas flame
burns blue and adjust the gas-to-air ratio when necessary
Kettles
Kettles are high-production, high-volume steam-heated pots most
frequently used by large institutional food service operations like
those found in hospitals and school cafeterias. They are well suited
for the production of soups, sauces, chili, vegetables, braised and
simmered meats, eggs, noodles, rice, and many deserts. The steam
heat cooks efficiently and in about one-third the time of a stockpot on
a hot top. Kettle capacities range from roughly 1 quart to 200 gallons.
They are available in these models:
·
floor mounted
·
cabinet mounted
·
wall mounted
Kettles provide an operator a method for cooking large quantities of
liquid foods such as soups, stews, jellos, etc. quickly and efficiently. They
also are designed so that these products can be readily decanted or removed
from the cooker without the back breaking lugging of traditional stock pots.
One of the primary advantages of cooking with a kettle is that it is
much less laborious than cooking over a hot stove. Also, since the kettle is
essentially a double boiler, there is no danger of scorching food, as there is
when cooking with direct heat. There is an inner shell and an outer shell in
the construction of the kettle. The outer shell can extend up the sides
half-way, two-thirds, or all the way to the top of the inner shell. This allows
the inner jacket to be heated up the sides to one-half, two-thirds, or full (to
the top). This provides many more square inches of heating surface than can be
obtained with a stock pot on a range. The stock pot can only be heated on the
bottom, and foods are subject to scorching and sticking. This is why kettles
require little supervision during the cooking process, and thereby save labor.
Kettles are either one-half, two-thirds, or fully jacketed. One-half and
two-thirds jacketed kettles make up the majority of the installations. The
steam jacket surrounds two-thirds of the kettle’s product-contact surface.
These units are usually deep and use a minimum of floor space. Fully jacketed
kettles are shallower and are usually selected for special-purpose cooking
situations because they reduce food crushing, as is experienced when boiling
potatoes, and they provide easier access to cooked products.
Types / Sizes
There are two types of kettles available to the foodservice operator.
Tilting / Stationary
Kettles come in a variety of sizes from 3 gallon to 120 gallon
capacities. Most kettles have a draw off value (tangent) in the bottom to
remove product. If it is a tilting kettle, there may be a draw off value in
addition to a pouring up. The pouring up helps to direct the product flow into
a pan or pot.
Tabletop Kettles
Tabletop kettles are mounted on a table, stand, or wall and are simply
smaller versions of the larger kettle. Stationary and tilting types are
available. Some can be ordered with mixer attachments and most larger kettles
should be ordered with a lid.
Trunnion Kettles
A trunnion kettle is a 20 to 40-quart cooker used predominately by
military and family-style food service establishments for re-heating pre-cooked
foods. See the discussion of "cook-chill" systems to see why these
are growing in popularity.
In military base kitchens, pre-cooked food arrives from the commissary
in a bag. These bags functions as both a package and a cooking container. To
prepare, they are placed directly into the kettle’s boiling water for
re-heating. This helps assure uniformity in the food preparation and minimize
the potential for bacterial contamination. Twenty- to forty-quart trunnion
kettles are available as either table top or special cabinet-mounted units.
Medium-sized models have tilting capabilities, so they are perfect for cooking
and serving vegetables such as green beans and corn. They also work well for
foods that are cooked and held for serving, such as soups.
Large kitchens, offering a wide selection of menu items every day, often
use several large kettles. This may present some interesting operational
challenges. Kettles exceeding 60 gallons are actually so large they require the
user to stand on a foot-stool to access the kettle contents. Very large kettle
units, up to 120 gallons in capacity, are wider and lower to the ground than
smaller units. This helps reduce potential dangers such as the cook falling
into the kettle.
Generally, the larger kettles, 80 gallon and above, require the addition
of a kettle mounted mixing motor. Hand mixing that much product becomes
impractical. For 60 gallons and under, a large paddle that looks like a ship
oar is used for stirring.
Components
Kettles are steam-heated vessels that cook by the transfer of heat from
the steam through condensation against the kettle walls. They are intrinsically
simple devices. Most kettles have a steam jacket that covers at least
two-thirds of the vessel. Some models have a steam jacket that covers 100% of
the kettle but these units are rare and are considered specialty applications
by most manufacturers.
The steam pressure in the vessel jackets is precisely controlled. Zero
pound (also called gauge pressure) steam at sea level produces 212°F heat, and
50-pound steam produces about 298°F. Higher pressures cook food faster, but
could run the risk of scorching. Many kettles have mixing arms to scrape the
inside heated surface to reduce scorching and to mix the food being cooked to
create a more uniform temperature. Safety valves are located around the top of
kettles to vent steam in the event that pressure rises above its setpoint,
preventing rupture of the steam jacket.
Condensed steam is drained from the vessel jackets using special control
valves and some kettles are piped, so that they are capable of alternating
between steam and cold water energy sources. These designs are popular for the
"cook-chill" concept discussed elsewhere in this program.
Efficiency
Saving Money
Common sense will eliminate most energy waste when using kettles. The
most common wastes are associated with improper steam system water chemistry,
which can result in premature heating-element failure, deviations in cooking
time and product quality, and even food scorching.
Operational common sense includes turning the heat source on only when
needed and repairing steam leaks as they are identified. Lids should also be
closed when possible to reduce heat losses.
NOTE: If the customer is cooking highly acidic based foods like tomato
sauces, they should order a kettle with a 316 type stainless steel inner liner.
This will prevent the metal from becoming pitted. Normally manufacturers use
308 type stainless steel which is more than sufficient for non-acidic based
products.
Ovens
There are 11 types of ovens
available to the foodservice operator. They are:
Oven cooking is as ancient as
civilization, as old as the baking of bread. It is no wonder that oven cooking
is still the most common form of food preparation around the world.
Consequently, ovens are one of the most widely used types of kitchen equipment.
The smallest establishments may have a microwave to heat appetizers or
sandwiches and the largest may have a conveyorized bake oven for high volume
production.
Ovens are available in a
variety of sizes and designs. Some are specifically designed for certain food
preparation tasks, while others are meant to serve a diverse range of cooking
applications. One of the most recent designs, called a Flash Bake oven, uses a
combination of high intensity visible light and radiant heat to increase
production speed and improve food preparation quality.
Cooking Process
The oven is one of the most
common and intuitive cooking technologies since most people are familiar with
residential units. First, the oven is preheated to the desired cooking
temperature. Next, food to be cooked in the oven is usually placed in
containers of metal or glass or on metal pans. Then the food is brought up to a
specified temperature for a certain period of time. The speed of this process
depends on the size of the food items heated, their geometry, and the rate of
acceptable heat transfer to them. For example, thin items like pizza obviously
heat much quicker than large items like whole turkeys, and a stuffed turkey
will take significantly longer to cook than an unstuffed turkey.
The actual cooking cycle may
also require changes in oven temperature over time for a given item cooked,
especially where surface browning is desired. For example, a recipe may call
for the majority of the baking at 325°F, but with the last few minutes at
425°F.
The most common cooking
process design is to surround the item being cooked in hot air. But air is a
relatively poor heat transfer agent, especially when compared to the speed with
which heat can be transferred by a griddle or by immersion in hot oil. This air
heat-transfer process can be sped up by circulating or blowing that air around
the food being heated.
Apart from air, some oven
designs use high intensity and infrared light, microwave energy or even steam.
Each design over time has developed a special niche in the preparation of
foods. No one oven design is ideal for all food preparation tasks and many
modern ovens incorporate a combination of these technologies.
Electric vs. Gas
There are many factors to
consider when selecting an oven: first cost, food preparation productivity,
ease of operation and heat generation in the kitchen, as well as the energy
source used: electricity or gas. Keep in mind that energy only accounts for 3
to 5 percent of a food service establishment's total costs. So, while one fuel
may be less expensive in a BTU to BTU comparison, the best choice in cooking
equipment is the one which minimizes total operating costs, not just energy
costs. Features that reduce labor costs or result in higher food product yield
will nearly always outweigh any energy considerations. Make sure that you
include all of these factors in any equipment evaluation.
Let’s take a closer look at
the energy use issues, remembering that comparisons should be made on the basis
of similar equipment where only the energy input is being changed. Electric
ovens generally offer these benefits:
Electric units are more
efficient so they add less heat to the kitchen, which ultimately must be
removed by the kitchen cooling system. Electric units require less maintenance,
require less ventilation, and are more portable. Electric ovens, especially
those with electronic controls, deliver more consistent run-quality and require
less operational supervision. They are also generally considered to be cleaner
and more flexible in their use (especially where maintaining oven humidity
levels is important). Flexibility in kitchen design and modification is also
achieved because venting may not be necessary. On the other hand, the primary
benefit of gas is that it is a less expensive fuel source than electricity.
Components
An oven is composed of a
box-like enclosure, heating elements, and controls. The enclosure ranges from a
counter-top size, to larger free-standing and floor model units. Ovens normally
have a hinged door at the front or side, and adjustable racks or trays to hold
food items. Conveyer ovens have openings on two sides. The quality and amount
of insulation, plus the presence of an air curtain to retain oven heat when the
door is opened, all affect energy efficiency and uniformity of heating.
Deck ovens and conveyer ovens
use convection as a heat transfer medium, but are named for the special large
heated deck where the food is placed throughout the cooking process. These are
commonly used for roasting, baking, and cooking pizza.
Electric heating elements may
be at the top, bottom, and/or the sides of the oven depending upon oven design.
Gas combustion chambers are also used. Steam is used in special oven designs to
shorten cooking times and improve certain food preparation. Yeast-raised breads
and pastries are often baked in humidity-controlled proofing ovens. Microwave
designs provide heating energy by channeling electromagnetic waves into the
oven and rotating the food items to assure uniform heating. Flash Bake ovens
use a combination of high intensity light plus infrared radiant energy for
extremely rapid heating.
Controls indicate desired
oven temperature and certain designs also provide "cook and hold"
cycles that greatly extend the time and improve the quality of food service.
Efficiency
Saving Money
The energy efficiency of
ovens depends upon how well they are constructed and used. Insulation levels
and quality are two of the most significant factors in oven design. Some
inexpensive ovens have little-to-no insulation in the oven door. In addition,
ovens consume considerable amounts of energy when they are left on, even when
no food is being cooked. This is due to losses through the oven walls and air
leakage around the door opening. These losses can be a significant component in
the operating cost, so remember to turn all oven equipment off, or at least to
a lower temperature, during non-operating intervals. This will save energy,
reduce cost, and increase oven life. When a food service establishment
production requirement does not call for a full sized oven, a half-size oven
may operate at much better economies.
Cook 'n' Hold Ovens
Convection Oven
Combi Oven
Convection Deck Oven
Microwave Oven
Conveyer Oven
Technology Types (Resource)
New Technologies
Gas and electric oven
manufacturers are continuing to improve oven insulation and controls, heat
transfer effectiveness, and heat recovery technologies. These improvements
result in higher efficiency and shorter times for ovens to come up to
temperature. Many of these newer designs also maintain a more uniform
temperature in the oven zones.
For example, conduction ovens
circulate a heat transfer fluid through plates to provide more accurate and
uniform heating. Also, Flash Bake technology is making dramatic inroads in the
preparation of many trendy foods, such as quesadillas and pizzas.
Electric Foodservice Council
Partners in Foodservice Solutions
Ranges
The range is perhaps the most versatile piece of cooking
equipment in a commercial kitchen. It can be used to
cook a wide variety of foods, primarily those requiring
the use of cookware such as pans, stockpots and skillets.
Many range units are also equipped with a conventional
or convection oven located below the cooktops, which
makes the unit even more versatile.
Cooking Process
The range cooks food by transferring heat to the
cookware, which in turn transfers that heat to the food
by conduction. The cookware is heated either by an
electric resistance coil, a gas or electrically heated solid-
top element, or by coming in direct contact with the gas
flame. Ranges can use a variety of cookware; however,
when solid-top elements or resistance coils are used, it’s important
that the bottom of the cookware be flat to allow a good contact between the
bottom of the pan and the elements. Rounded bottom pans reduce the amount of
heat transferred to the pan.
Gas open-top units apply a flame directly to the bottom of the cookware.
The chef controls the temperature by adjusting the height of the flame, which
provides the visual feedback many chefs have become accustomed to. Gas units
can typically be used with any type of cookware.
Solid-top units or flat-top units can be heated by electric resistance
coils or gas burners. While these units take several minutes to preheat, they
provide a very uniform temperature across the surface of the plate. Heat from
the plate transfers to the cookware by conduction. Solid-top gas units are much
less efficient than their open top counterparts because the plate must heat up
before transferring heat to the cookware. Plus, with greater preheat time,
these units are typically left on while other types of units could be turned
off when not used.
Performance
Cooking on a range can be more of an art than a science. The experienced
chef knows that it takes finesse to get the best performance out of a range.
For this reason, less experienced food service operators can have a hard time
producing consistent food product quality. There is no substitute for trial and
error in learning how to adjust temperatures to cook properly and produce a
tasty end product. In most cases, it’s important that cookware have a flat
bottom that makes good contact with the hot top or electric resistance coils.
Electric vs. Gas
Cooking technique on a range is learned largely by trial and error. That
is why chefs are resistant to change after perfecting their craft. Most prefer
to use the same type of units that they were trained on. Chefs trained on gas
equipment are likely to prefer gas, and reluctant to adopt electric ranges or
even electric induction ranges. The same holds true for the experienced
electric range users.
However, there are many factors to consider when selecting a range:
first cost, food preparation productivity, ease of operation, and heat
generation in the kitchen, as well as the energy source used: electricity or
gas. Keep in mind that energy use only accounts for 3 to 5 percent of a food
service establishment?s total costs. So, while one fuel may be less expensive
in a BTU to BTU comparison, the best choice in cooking equipment is the one
which minimizes total operating costs, not just energy costs. Features that
reduce labor costs or result in higher food product yield will nearly always
outweigh any energy considerations. Make sure you include all of these factors
in any equipment evaluation.
Let’s take a closer look at the energy-use issues, remembering that
comparisons should be made on the basis of similar equipment where only the
energy input is being changed.
Electric ranges are generally considered to be:
More efficient, so they add less heat to the kitchen. This is heat that
must ultimately be removed by the cooling system.
Electric units are less prone to cause fires when grease spills over
onto the range.
They require less maintenance and less ventilation.
Electric induction units offer the highest energy efficiency, come up to
full temperature very quickly, and offer precise temperature control. These
units are also safer for food service operators because the surface never gets
hot.
Gas or propane ranges are generally considered to offer the advantage of
a cheaper energy source. Some chefs prefer gas units because they can control
cooking temperature simply by adjusting flame height. Also, because many chefs
are trained using gas cooktops, they will most likely prefer a unit which most
closely matches their skills.
Components
Cabinet
Range equipment is available in many different sizes and configurations.
Most units are 36 inches high and 30 to 32 inches deep and vary from 18 to 60
inches wide. Smaller units contain only 2 cooking elements while larger units
can contain more than a dozen cooking elements. Ranges can be free-standing or
mounted over an oven or cabinet base. Free-standing units often sit on a
counter top and are sometimes called cooktops.
Open Top
Several different types of cooking elements are available for both gas
and electric energy sources. The most common is the open-top element.
Open top gas burners have a steel or cast iron grate that holds the
cookware in place. Gas burners located below the grate produce a flame that
directly contacts the bottom of the cookware. Open burners provide precise
temperature control by adjusting the height of the gas flame and require no
preheat time. Each burner is individually controlled by a gas valve located on
the front of the unit.
The comparable electric unit is commonly known as the open coil hot
plate. The cookware rests on an electric resistance coil, which when heated,
transfers heat directly to the bottom of the cookware. These units usually take
a few minutes to reach full operating temperature and a few minutes to cool
down when turned off. Each cooking element has a separate thermostat
controlling temperature.
Hot Top
Hot-top ranges use the energy source to heat a thick metal plate rather
than the cookware directly. These units are equipped with a 12 to 18 inch square
plate about one-half to one inch thick. The energy source may be electric
resistance elements or gas burners. In either case, the heat source heats up
the metal plate. Cookware placed on this plate then heats by conduction from
the plate. Since two separate stages of heat transfer are involved, these units
are typically much less efficient than open-top designs. Plus, the plate can
take 30 to 60 minutes to preheat and cool down. Therefore, chefs typically
allow these units to continue operating even during slow cooking periods.
French Plate
The French plate falls somewhere in between the open-top and the
hot-top. They are most often electric. The cooking element is a round plate
about 6 to 10 inches in diameter. The plate heats up from electric resistance
coils or gas burners mounted to the bottom. The plate provides even heat
distribution and each "eye" is controlled separately.
Induction
The electric induction range is significantly different from the other
types of ranges. Induction coils located under a ceramic surface induce an
electric current in the cookware. These units offer precise temperature control
and are more efficient because they heat the cookware directly rather than the
range surface. The ceramic surface is durable enough to sustain heavy use even
when sautéing. These units are by far the most energy efficient type of range
available.
Accessories
Manufacturers offer a variety of optional features for the conventional
range. Some units are combined with a conventional or convection oven, griddle
or charbroiler. Some provide space for holding cooked food. Some manufacturers
offer units with a combination of different cooking elements such as hot tops
and open tops. Many ranges also have a shelf or a salamander broiler attached
to the back of the unit.
Types
Heavy Duty
Heavy duty ranges are designed for large, heavy stockpots and other
cookery. They are ideal for the high-volume production requirements in large
restaurants and institutional and industrial kitchens. These units are
typically smaller than conventional units, measuring 36 inches wide and are
available in modular units with oven bases, open cabinet bases, or table tops
alternatives. Configurations vary by manufacturer, but some include other
features such as fryer sections, salamander broilers, ovens, and griddles.
Restaurant
Restaurant ranges are designed for a lighter duty cooking requirement
than the heavy-duty range. Even though the total size of a restaurant range
will generally exceed that of a heavy duty unit, they are more suitable for
smaller operations and short order cooking. The larger size accommodates more
cooking elements capable of supporting lighter cookware. Configurations vary by
manufacturer. These units are available in lengths up to 72 inches and are
often combined with a cabinet base or oven unit, salamander broilers, and
griddles.
Specialty
A variety of specialty ranges are available to suit specific food
preparation needs.
The Chinese range is built for wok cooking. Some of these have water
spigots and drain troughs to make cleaning easier.
A stockpot range is designed for very large stockpots and is typically only
24 inches tall to allow the food service operator access to the large pot.
Taco ranges are also available for the unique task of preparing the
contents of a taco.
Technology Types
New Technologies
Electric induction ranges represent the latest in technological
advancement for the kitchen. These units heat quickly, offer very precise
temperature control, and are considered safer because the cooking elements
don’t get hot. These units are also the most efficient, transferring up to 90%
of their energy to the cookware.
Efficiency
Saving Money
The initial cost of a range is rarely the most significant factor in
making a purchase decision. Those who select light equipment due to lower cost
often discover, after the fact, that these units are insufficient for the kind
of production they had intended. A range should be chosen on the basis of the
following six characteristics: capacity, versatility, temperature consistency,
serviceability, ease and economy of required cleaning, and over-all
dependability.
Here are some tips on how to operate the equipment in a way that saves
money:
·
Make sure the bottom of the pot rests
flush against the heating surface.
·
After the pot comes to a boil, turn the
heat down to a level that maintains a simmer. Food will not cook any faster if
you add more heat. That just wastes energy.
·
Cover the pot with a lid to retain
heat.
·
Always cook at the lowest possible heat
level that yields satisfactory food product.
·
Turn the unit off, or at least reduce
its temperature when not in use.
·
For closed-top units, preheat only as
needed.
·
Heat only the section of the closed-top
unit being used.
·
Group pots on closed top ranges to use
as little surface area as possible.
·
Here are some energy saving tips
specific to gas equipment:
·
Adjust the flame until it is entirely
blue. A yellow-orange tip means you are using too much gas and some of it is
not burning completely.
·
Gas flames should just cover the bottom
of the pot. Flames extending beyond the pot bottom are dangerous and waste
money.
kitchens for such tasks as stock-pot cooking, stir frying, and sauteing
a variety of foods, including hot cereals, gravies, sauces, soups, and
vegetables. The design of these useful appliances continues to evolve as
commercial users seek more powerful and energy efficient equipment.
Cold Kitchen Equipment
We offer all-inclusive range of cold kitchen
equipment such as water cooler, display counter, pantry fridge, and cold bain
marie counter. In addition, we also offer four door refrigerators and
commercial under counter refrigerator to our clients. These cold kitchen
equipment are based on innovative cooling technology, which ensures their
efficient performance over a longer timeframe. All the cold kitchen equipment
have stainless steel construction, which ensures their durability.
Our range of cold kitchen equipment comprises:
We are engaged in manufacturing
and offering cold bain marie counter that has innovative designs, to meet the
diversified requirements of commercial kitchens. Constructed with stainless
steel, these bain marie counter are extremely durable. It has a glass
covering on upper side, which ensures clear display of the food items kept in
it.
Its specifications are as follows:
·
Item Code: VIE-505
·
Capacity: 300 ltr
·
Size: 60” x 27” x 34” +18” (can be customized as
per client’s specifications)
·
Power Consumption: 430 WT
We offer commercial under
counter refrigerator which is specially designed to provide consistent and
better cooling to different types of food items as well as beverages. These
commercial under counter refrigerator have a compact design, and spacious
interiors. This also assists in providing better storage and cooling
capacity. Having stainless steel finish, these commercial under counter
refrigerator operate with the assurance of minimal energy consumption.
    |
D. Modern
developments in equipment manufacture
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