5 Equipment for Quantity Food Production

S. Uma Mageshwari

1.    Introduction

Equipments are essential features of every ones everyday activities and their need varies with the individual and their exposure. The term “equipment” means all machinery, tools, utensils, crockery, cutlery and furniture that are used for preparation, service and storage of food

Catering industry is a most challenging industry among all the other industries in the world as it involves both human and non human resources a lot. Recently, there is a tremendous growth in food service industries and their mode of operation and facilities they offer. They cater every nook and corner of the world with various needs and wants. This is possible by them only by the way they have made use of the versatility of the equipments and facilities they found around them.

Catering industry, being a large scale business sector operates a heavy quantity of raw materials for production and service, requires more number of non human resources especially equipments and accessories to finish the task efficiently. The requirements are almost similar to the equipments what we require at home but due to the greater quantity, durability, speed, efficiency and economy and of course they would be bigger in size.

Over the years there is a tremendous change in the usage and availability of equipments for quantity food service organizations.

2.Objectives

The present unit deals with

• The types of equipment available to the caterer.
• How they can be suitably selected and purchased.
• It also provides important guidelines for their operation and maintenance with special reference to hygiene and the economical use of time, effort and money.

3.  Classification of equipment

Equipment are being classified in a number of ways, according to weight or size, the order in which it is used in the production cycle of a catering establishment or according to their mode of operation.

3.1. Equipments category based on weight or size

Catering equipments are vary in size and heaviness based on the size and type of establishment. The establishment that serves less customer that require lesser capacity equipments than the one that caters a huge mass. Hence based on the requirements and application these are classified into three as “heavy duty”, “medium duty” or “light duty” equipments.

The heavy duty equipment is the one that is generally too heavy in weight and fixes in a place permanently for a while. Or they may be working for long duration too. These are mostly made by heavy metals. Production equipments such as cooking ranges, ovens, mixing machines and grinders, boilers and steamers, cleaning equipments such as vessel washers are great examples of heavy duty equipments.

Medium duty equipments are not too difficult to move but they can be separated or pushed for occasional cleaning. They are attached with wheels to move around and with replaceable parts .Examples are wet grinders, working tables, driers, dish washers, trolleys, and mobile serving units.

Light duty equipment smaller, lighter and easily handled and moved around or placed anywhere when required for use. All other equipments that are used inside the kitchen and all the other food production cycle areas come under this category.

It is evident that the three categories of equipment provide a wide range for the use of large, medium and small sized catering establishments.

3.2.Category based on order of use in production cycle

Number of steps involved in production cycle, and thus the items that are used in these places are also named after those activities.

Receiving equipments: These are used in the goods receiving area mainly to collect, check and received the items supplied by the seller to the organization. These include receiving platform, weighing scales, trolleys, sinks, tables, cupboards and so on.

Storage equipments: Racks, shelves, bins, jars, scales, and machines, portable bins for storing flour, sugar, rice, and pulses are essential to keep and preserve the goods stocked in the stores of an organization. Generally this is one of an area where limited equipments are used.

Kitchen equipments: Kitchen is the heart of a food service establishment wherein the core activity of the entire establishment. As the core activities are being held here the number and varieties of equipments are also more here. The essential tasks that are carried out here are preparation, cooking, holding, and serving of food and washing up. Kitchen equipment would therefore consist of tables or work surfaces; peeling, cutting grating and slicing equipment; oven, grill, cooking range, hotplate, chapatti, puffer, etc. for cooking; bain-marie, trolley, serving dishes, trays, crockery and cutlery for holding and serving.

Washing-up equipment may include sink units, dish washers and driers, instant boilers for hot running water depending on the size of the establishment. Plates 2-5 indicate a wide range of available catering equipment.

Complete washing-up units are now available in stainless steel in place of the old sink connected to a water tank on one side and a waste pipe on the other. The complete units now provide free flowing water and underground drainage.

Equipment for waste disposal has been transformed from the open dumps to the closed bins, sealed bags and incinerators. The latter come in sealed units which can be fitted into dinks to crush any plate waste and peeling that may be passed through the sink. Incinerators are also available as separate free-standing disposal units meant solely for dealing with waste materials.

This method of classifying equipment is the most commonly used one as it helps to relate equipment with the area in which it is to be installed and the use to which it is put.

3.3.According to mode of operation

Depending on whether the equipment is fully hand-operated, semi-automatic or fully automatic, the various pieces such as beaters or whisks, hand slicers, etc which require greater effort to use than the semi-automatic types. The later use electrical energy but need to be monitored carefully. These include mixers, electric whisks, fryers, etc

3.3.1.   Automatic Equipments

Automatic types include sophisticated equipment with thermostatic controls, timers, etc. which can be adjusted to required times and temperatures. The latter two categories are motorized and therefore require less attention and effort to operate. Their output in terms of the number of units of food prepared is also more than the mechanical and semi-automatic types of equipment.

3.3.2.   Modular equipments

The equipments and its parts if it is made as interchangeable with another equipment is called modular equipment. These are very popular nowadays as it saves time, energy and money. Usually pans in different sizes are fit into oven for baking as well as in refrigerator for storage and in trolleys in cold room.

Standard size of trays are 30 cmX40cm or 22cmX30cm.Modular equipments play several role in food management like they avoid repeated handling, usage of less cleaning materials increase the work efficiency and improve the food quality.

3.3.3.   Multipurpose equipments

A single equipment used for several purpose are called multipurpose equipments.A food processor with several attachments like chopper blade,grater,peeler,dough making chamber could help the establishment to save the money invested by saving space and duplication of equipments. Similarly steamers, boilers. also called as multipurpose equipments. These equipments are very useful to the small food service outlets. Even an efficient employee of an establishment can also create new multiuse equipment.

3.3.4.   Mobile equipments

The equipments that are moved from one place to another is called mobile equipments. Trolleys, Wheels under the big grinders, working table, ovens with wheels are good examples of these.

3.3.5.   Labor saving devices

Equipments that require less man power are called LSD. .They produce quality standardized product through making Examples are peelers, scrappers, vegetable choppers. Maximum work out put with limited manpower that are used in these equipments.

3.3.6.   Custom Built Equipments

A piece of equipment assembled and fixed on the floor is called custom build equipments. Mostly large heavy duty equipment are custom build. As it is manufactured as per the requirements of the organization its costly and most recommended for industrial food service and hostel mess and so on. Boilers, steamers, chilling are all some of them.

Whatever may be the method of classifying equipment, it is important to remember that every food service establishment will have different needs in terms of size, numbers and types of equipment required. While the same piece of equipment may be fixed in one establishment it may be freestanding or mobile in another.

4.    Factors involved in selection of equipment

Some basic factors are important in making decisions for selection of equipment for any catering establishment. These include: (a) size and type of the establishment, (b) menu, (c) purpose for which it is used, (d) utility in terms of design and the frequency of use, (e) price, (f) ease of installation, maintenance and operation, (g) safety, (h) economy (i) ease of cleaning (j) attractiveness and (k) source of supply

4.1.Size and type of establishment

Size refers to not only the spatial measurements of the structure or promises for food preparation and service activity but also to the number of customers that must be catered to at a time. Thus, selection of equipment is directly affected by the volume of food prepared, as this has to be related to the size or capacity of the particular piece of equipment. Too large equipment in relation to turnover expected will lead to under-utilization and inefficiency, while too small a capacity will not be able to meet the demands of the customers.

The smaller the size of the establishment the more important it becomes to utilize space to the maximum. This is made possible by selecting equipment not only on the basis of its mobility but also its ability to be flat packed and stored when not in use.

For small-or medium –sized establishments it is a good idea to select multifunction equipment such as griddles which can be used for making do as (fermented batter pancakes), eggs, chapattis and cutlets. Similarly, steamers for vegetables, poaching eggs or making idlis (steamed fermented batter preparation) are useful pieces in any kitchen.

The type of establishment reflects the extent of service offered to customers in terms of the quantities and different types of foods prepared and served at one time. For instance, heavier duty equipment of larger capacities will be selected for college hostels serving a relatively fixed menu at a particular time. Than for the preparation and service of short order lunch served over a counter. Again, a cafeteria will require more types of equipment of smaller capacities; with greater emphasis on beverage service or snacks than cooked items prepared in quantity.

4.2.Menu

Equipment also depends on the methods of cooking required for the dishes planned to be served. For instance, is a canteen menu consists mainly of fried snacks and beverages the selection will be between investing on a fryer or a simple “ kadai” (a vessel the shape of a Chinese “vok” placed directly on the source of heat). On the other hand, if the menu consists of ready items, sautéed or shallow fried snacks and sandwiches, a fryer would be unnecessary.

Menu patterns also greatly affect the serving equipment to be selected. For example, the size and number of inserts to be selected for hot food service counters will depend on the number of hot foods appearing on the menu as also the number of portions used at peak times.

The form in which the food is to be purchased will also influence the selection of equipment for any establishment, for example, if ready idli, vada, dosa mixes are purchased for preparing the dished for a particular menu, than there would be no need for a particular menu, then there would be no need for a wet grinder which would be necessary if the mixtures were prepared from raw ingredients. Similarly, if quick frozen vegetables are used in the preparation of meals, there would be no need to select equipment like vegetable peeling machines.

It must, however, be remembered that while menus can be changed easily an equipment is an expensive matter. Its selection therefore needs to be carefully planned to provide menu flexibilities. Multifunction equipment is good choices and can easily take care of menu variations.

4.3.Purpose for which the equipment is used

Every equipment selected for particular task must be able to fulfill that specific purpose, contribute the efficiency of production, profitability, convenience or customer satisfaction in terms of aesthetically presented meals, more value for money or comfortable serving and eating.

There are a number of spaces and labor-saving equipment available on the market which can perform different functions simply by the use of attachments to the main machine, like for kneading, beating, mixing, grating and slicing can be fixed for use when required. Such multifunction devices are ideal for small outlets like coffee shops, canteens or lunch rooms.

4.4.Utility in terms of design and frequency of use

The design of a piece of equipment has to be considered in terms of the results desired. For example, it is very important to know if a piece of equipment is actually maintaining the temperature necessary for keeping food safe while holding it or in storage. But it is very difficult to know this in the case of certain equipment unless the manufacturer indicates clearly the temperature at which the equipment is designed to operate.

In selection, designs which have temperature indicators and warning lights should be preferred, because equipment tested in the manufacturer’s laboratory may work differently in the catering environment.

The selection of a particular piece of equipment will be affected by how often it will be used. For instance, there is no point going in for a wet grinder if fermented items of food requiring wet grinding are placed on the menu once in a fortnight or a month. It would be wiser to select a kitchen machine which can be used for wet grinding when required and for blending, grating and other functions as well.

4.5.Price

The cost of a piece of equipment almost always determines buying choice. The material of which equipment is made affects its price and rate of depreciation along with sanitation, satisfaction and usefulness in terms of suitability and hard wearing must be thoroughly assessed. The rate of depreciation and the rate of return on investment are also very crucial considerations.

Selection is also guided by the funds available to the buyer over a period of time. This is because he has not only to pay the initial cost of the equipment and installation but also recurring costs for operation, care and maintenance necessary for every equipment whatever its size. The larger the budget the wider becomes the choice of the buyer.

4.6.Ease of installation, maintenance and operation

It is more expensive to buy equipment which needs a specialist’s attention each time something goes wrong. Selection of equipment must be guided by simplicity of construction, case with which it can be operated by the existing skills of catering staff, and the factors which are important to hygiene and safety of both equipment and its environment factors such as the materials from which the equipment is made, the nature of the construction in terms of rounded edges, proper insulation, earthling and plumbing as the case may be.

As far as the operation is concerned most catering staff should be able to acquire the skills to operate equipment quite easily. If sophisticated auto controls are provided then the personnel need to be trained in their use and cautioned against the dangers of ruining the equipment and causing accidents due to negligence. In such cases instructions in the form of simple steps clearly pasted on the door of the equipment or on the wall above it help operators to depend less on their memory and avoid unnecessary expenses and trouble. In the long run this helps to make work more productive and satisfying to both management and staff.

4.7. Safety

Since catering involves dealing with heavy equipment, sharp tools, glass and cutlery, large volume of food, electricity gas hot and cold water, it is extremely important to select equipment that is guaranteed for safety both when not in use and while in operation. All sharp edged and movable parts should be provided with safety guards. There should be no crevices which may harbor dust, dirt and therefore microbes, endangering the safety of the environment and the food produced.

In selection of equipment for safety the doors should open opposite the area where dishes are to be placed, so that accidents are avoided by the doors coming in the way of working. While deciding on cooking equipment, models of cooking ranges with concealed electric elements should be selected with due regard to the safety of all working in the environment who may touch the heated plate accidentally, not knowing it has just been put off.

4.8.Economy

Economy refers to the amount of fuel in terms of electricity, gas, coal, etc. which equipment may require for functioning. The operating costs of a piece of equipment are an important consideration in its selection. In certain areas, for example, electricity may be cheaper as a cooking fuel than gas or coal. In such cases it would be better to select electrically operated equipment rather than gas ranges. Equipment to consider in terms of energy saving would be pressure cooking equipment, convection and microwave ovens for quick cooking and even heating. In addition the costs of installation, maintenance and operation will determine the selection. It would be wiser to select equipment with higher initial costs and lower maintenance costs than go in for cheaper models which have higher recurring costs.

4.9.Ease of cleaning

The appearance of equipment plays an important role in attracting a workers attention to it and creates a desire for using and looking after it. It is thus a morale booster especially in areas of activity where the work is generally uninteresting and unrewarding. For instance, in the vegetable preparation centre of a kitchen where the monotony of peeling and cutting grows progressively, the introduction of vegetable peeling machine makes the job a bit more varied and less cumbersome. Again, in the dishwashing area, a dishwasher can help to create a little interest in the otherwise uninteresting routine.

5.      Care and maintenance of equipments

5.1.  Schedule for care of equipment

• Keep all equipment.
• Wash all removable parts of equipments with suitable detergent and hot water after each use. In tropical summers this is not necessary as the water in the raps is usually warm to hot depending on the environmental temperature. After washing wipe equipment completely dry before replacing.
• All small equipment like cutlery, ladles, chopping boards, kitchen tools, etc. should be washed after use as in (2) and replaced in drawers and racks built for the purpose and covered to prevent them from dust or dirt during storage.
• Check that all pieces are in working order. Close supervision at work is necessary to ensure careful handling and to detect any deviations from effective operation, like an unusual sound, or fusing of warning lights, or ineffective thermostatic controls.
• Repairs must be attended to without delay to prevent the equipment from giving way and disrupting work for any period of time.
• A weekly, fortnightly or monthly programme for oiling or servicing the equipment to maintain movable parts or machinery in order is important. The service instructions provided by the manufacturer along with the equipment are a good guide to the service procedure that should be followed. It is useful to prepare instructions in as simple a form as will be understood by the operators of the equipment. This card could be kept near each major piece of equipment.
• All electrical inputs to the equipment should be checked periodically to ensure that proper electrical load is available foe efficient functioning.
• Insulations, plumbing and other connections need regular checks to keep equipment running at optimum efficiency.
• Make full use of warranty periods to help train organization staff to learn regular maintenance procedures from the manufacturer’s engineers.
• Assign the care of each machine to one responsible person.

Money, time and effort spent on care helps to maintain equipment in continuous working order while that spent on care helps to maintain equipment in continuous working order, while that spent on repair can mean interruption in work causing unnecessary strain on staff, in addition to extra costs..

Thus, if equipment is cared for systematically and proper procedures followed, maintenance follows on its own prolong the life and optimum usage of the equipment.

5.2. Cleaning schedules

The cleaning schedules for some commonly used equipment in small food service establishment are given under their respective heads:

6.1.2. Cooking Equipment

Cooking equipment varies widely in size, shape and design and therefore requires separate treatment in terms of cleaning.

• Burners must me cleaned and pours must be checked thoroughly.
• Use liquid wax for enamel finishes
• Brush the inner parts thoroughly

6.1.3 Holding Equipments

•  Refrigerators outside should be cleaned daily, inside must be checked for spillage, or While cleaning the refrigerators it should be disconnected from the electrical supply
• damage of things an cleaned once in week
• Bain-marie and food warmers to be switched off after the service are over.
• Clean them using light detergent and  empty the equipments and soak them in

6.1.4 Preparation Equipment

• All removable pars should be dismantled and cleaned every time after use
• Sharp edges should be handled carefully while cleaning
• Sodium carbonate and hard brush must be used to clean up the coffee urns to avoid staining

6. Conclusion

Equipments are the basic operational resource that supports