Chapter 6 Food Production Functional Subsystem Food Production

Chapter 6 Food Production

Functional Subsystem: Food Production l Food production is the preparation of menu items in the needed quantity & with the desired quality. l Quantity – Distinguishes foodservices production from home or family food preparation. l Quality – Aesthetic, nutritional, & microbiological safety aspects of a food product. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Subsystem Objectives Primary: Transform human, material, facility, & operational resources into outputs. l Secondary: l l l Product/service characteristics Process characteristics Product/service quality Efficiency: l l Effective employee relations & cost control of labor Cost control of materials Cost control of facility use Customer service: l l Produce quantities to meet expected demand Meet delivery date for products or services © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Decisions l Includes forecasting, planning, & production scheduling. l Synthesis of quantity, quality, & cost objectives. l Product characteristics l Production process characteristics l Establishment of standards of quality © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Forecasting l Primary result of forecasting should be customer satisfaction. l Production Demand Overproduction – Production of more food than is needed for service. l Underproduction – Production of less food than is needed for service l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Forecasting l Quantity Demand Estimate number of customers or the number of servings. l Essential to use suitable forecasting model. l Examples: l Historical records l Intuition l Complex models requiring large amounts of data l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Forecasting l Historical Records l Effective production records should include: l l l l Date & day of the week Meal or hour of service Notation of special event, holiday, & weather conditions Food items prepared Quantity of each item served Provide fundamental base forecasting quantities when the same meal or menu item is repeated. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Forecasting Models l Criteria for a Model: l l l Cost – expenses of both development & operation. Required accuracy – accuracy of its predictions of future occurrences. Relevancy of past data – relationship of past & future data. Forecasting lead time – length of time into future the forecasts are made. Underlying pattern of behavior – actual occurrences follow some known pattern. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Types of Models l Most common model categories: Time series l Casual l Subjective l l Trends & seasonality in the data must be considered. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Time Series Model l Assumption that actual occurrences follow an identifiable pattern over time. l Suitable for short-term forecasts. l Frequent time series models: Moving average forecasting model l Exponential smoothing forecasting model l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Moving Average Forecasting Model First point: average of number of portions sold for the last five or more times the menu item was offered. l Second point: average of dropping the first number & adding the most recent number of portions sold to the bottom of the list. l Continue process for all data. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Moving Average Forecasting Model © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Exponential Smoothing Forecasting Model l l All past data are considered in smoothing process. More recent data are given more weight. Requires only a few pieces of data to update a forecast. Easily programmed & is inexpensive to use. Rate at which the model responds to change can be adjusted mathematically. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Casual Model l Assumption that an identifiable relationship exists between the item being forecast & other factors. l High costs for development & use. l Popular for medium- & long-term forecasts. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Regression Analysis Forecasting Models l Most commonly adapted. l Includes: Dependent variables – items being forecast. l Independent variables – factors determining the value of the dependent variables. l l Requires a history of data to permit plotting over time. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Subjective Model l Used when relevant data is scarce or patterns & relationships between data do not tend to persist over time. Delphi technique l Market research l Panel consensus l Visionary forecast l Historical analogy l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Scheduling Time sequencing of events required to produce a meal. l Planning stage: l l Forecasts are converted into the quantity of each menu item to be prepared. Distribution of food production to supervisors in each work center. Action stage: l l Supervisors prepare a production schedule. Items are assigned to specific employees. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Schedule l Should include: l l l l l Employee assignments Preparation time schedule Menu item Over- & underproduction Quantity to prepare: forecast amount for each menu item. Substitutions Actual yield: portion count produced by the recipe. Additional assignments Special instructions & comments Pre-preparation © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Meetings l Should be held daily with employees in the production unit. l Employees encouraged to discuss the effectiveness of the schedule. l Free discussion of work loads. l Conclude with discussion of the production schedule for the following three meals. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Ingredient Control l Begins with purchasing, receiving, & storage of foods. l Continues through forecasting & production. l Ingredient assembly – area designed for measuring ingredients. l Standardized recipes – provides assurance that standards of quality will be consistently maintained. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Advantages of Centralized Ingredient Assembly l Contributes to the cost reduction & quality improvement. l Redirection of cooks’ skills away from collecting, assembling, & measuring ingredients to production, garnishing, & portion control. l More efficient use of labor. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Centralized Ingredient Control l Control of unused portions is facilitated because storage is located centrally rather than in various work units. l Ability to combine tasks for two or more recipes using similar ingredients. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Function of the Ingredient Room l Primary function is to coordinate assembly, pre-preparation, measuring, & weighing of the ingredients. l Availability of appropriate equipment will help determine the activities to be performed. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Ingredient Room Organization l Should be located between the storage & production areas. l Necessary equipment includes: Refrigeration l Water supply l Trucks or carts for assembly & delivery l Worktable or counter l Scales l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Ingredient Room Staffing l Employees must be: Literate l Able to do simple arithmetic l Familiar with storage facilities l l Responsible for receiving, storage, & ingredient assembly. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Ingredient Room Staffing l Ingredient assembly personnel considerations: l l l l Size of operation Frequency & time of deliveries Size of ingredient room & location of other storage areas Type, number, & complexity of menu items Number of workstation to be supplied Schedule for delivery of ingredients to production & serving areas Extent of pre-preparation performed in ingredient assembly area © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Future of Ingredient Rooms l Centralized or food factories are being used for procurement & production. l Prepared menu items are distributed to several remote areas for final preparation. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Recipe l Formula by which weighed & measured ingredients are combined in a specific procedure to meet predetermined standards. l Written communication tool that passes information from the foodservice manager to the ingredient room & production employees. l Quality & quantity control tool. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Recipes l Recipes include: l l l l l Name of food item Total yield Portion size & number of portions Cooking time & temperature List of ingredients in order of use Amount of each ingredient by weight, measure or count Procedures Panning or portioning information Food safety (HACCP) guidelines. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Format l All recipes in an operation should be in the same format. l Common large quantity formats: Block format l Complete block format l Modified block format l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Block Format l Ingredients listed on left side of recipes. l Procedures directly opposite ingredients on right side. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Complete Block Format l Horizontal lines separate each group of ingredients with procedures. l Vertical lines separate the ingredient, amount, & procedure columns. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Modified Block Format l Most common l Horizontal lines separate the required ingredients for each procedure. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Format l Additional information often added at bottom or on back: Approximate nutritive values per portion l Variations on the recipe l Special serving instructions l Storage requirements before & after service l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Format l Recipes should be in large print easily readable from 18 -20 inches. l Recipe name should be in bold letters. l Major categories (breads, meat, salad, etc. ) may be color coded to make identification easier. l KEEP BACKUP OF RECIPES!!! © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Standardization l Ideal to have recipes that consistently deliver the same quantity & quality product when followed precisely. l Recipe standardization – process of tailoring a recipe to suit a particular purpose in a specific foodservice operation. l Requires repeated testing. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Justification l Advantages for using standardized recipes: Promote uniform quality of menu items. l Promote uniform quantity of menu items. l Encourage uniformity of menu items. l Increase productivity of cooks. l Increase managerial productivity. l Save money by controlling overproduction. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Justification l Advantages (cont. ): Save money by controlling inventory levels. l Simplify menu item costing. l Simplify training of cooks. l Introduce a feeling of job satisfaction. l Reduce anxiety of customers with special dietary needs. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Three Phases of Recipe Standardization l Standardized recipes: Developed for use by a foodservice operation. l Found to produce consistent results & yield each time prepared. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Three Phases of Recipe Standardization © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Recipe Verification l Review components of the recipe Recipe title l Recipe category l Ingredients l Weight/measure for each ingredient l Preparation instructions l Cooking temperature & time l Portion size l Recipe yield l Equipment to be used l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Recipe Verification l Make the recipe l Verify the recipe yield l Record changes to the recipe © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Product Evaluation l Informal Evaluation: Visual appearance l Flavor l Ability to obtain ingredients l Cost per serving l Labor time l Availability of equipment l Employee skill l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Product Evaluation l Formal Evaluation l l l l Select group of staff members & customers as a taste panel. Choose or develop an evaluation instrument. Prepare sample recipe. Set up sampling area. Sampling & evaluation of products. Summarize results. Determine future plans for the recipe. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Quantity Adjustment l Methods include: Factor method l Percentage method l Direct reading measurement tables l l Computer software also available © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Factor Method l Change ingredient amounts to whole numbers & decimals. l Divide desired yield by the recipe yield to determine the conversion factor. l Multiply all recipe ingredients by the conversion factor. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Factor Method l Reconvert decimal unit back into pounds & ounces or quarts & cups. l Round off amounts to quantities simple to weigh or measure. l Check math for possible errors. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Percentage Method l Convert all ingredients from measure or pounds & ounces to tenths of a pound. l Total the weight of ingredients in a recipe after each ingredient has been converted to weight in the edible portion. l Calculate the percentage of each ingredient in the recipe in relation the total weight. l Check the ratio of ingredients. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Percentage Method l Establish the weight needed to provide the desired number of servings. l Add handling loss to the weight needed. l Multiply each ingredient percentage number by the total weight to give the exact amount of each ingredient needed. l Convert to pounds & ounces or to measures. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Direct Reading Measurement Tables l Quick to use & require no mathematical calculations. l Used to adjust weight & volume of ingredients in recipes that are divisible by 25. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Adapting Home-Size Recipes l Special considerations are necessary: Know exactly what ingredients are used & in what quantity. l Make the recipe in original home-size quantity. l Evaluate the product for acceptability. l Proceed in incremental stages in expanding the recipe. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Adapting Home-Size Recipes l Special considerations are necessary: Determine handling or cooking losses (5%8% loss is typical). l Check ingredient proportion against a standard large quantity recipe. l Evaluate products using taste panels. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Quantity Food Production l Involves: Control of ingredients l Production methods l Quality of food l Labor productivity l Energy consumption. l l Sweet Spot – point of best value at lowest cost. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Objectives of Food Production l Primary reasons to cook food: Destruction of harmful microorganisms l Increased digestibility l Change & enhancement of flavor, form, color, texture, & aroma l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Heat Transfer l Conduction – the transfer of heat through direct contact from one object to another. l Convection – distribution of heat by the movement of liquid or vapor. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Heat Transfer l Radiation – generation of heat energy by wave action within an object. l Induction – use of electrical fields to excite the molecules of metal cooking surfaces. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Moist Heat l Use of water or steam for the cooking process. l l l Simmering or stewing – cooking in a liquid that is boiling gently (185º-205º F). Poaching – cooking in a small amount of liquid that is hot but not bubbling (160º-180º F). Blanching – cooking an item partially & briefly. Braising – cooking food in a small amount of liquid, usually after browning it. Steaming – cooking food by exposing them to direct steam. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Dry Heat l Use of dry air, hot metal, radiation, or a minimum amount of hot fat for the cooking process. l Includes: Broilers – heat source 3”-6” from food. l Deep Fat Fryers – food immersed in tank of oil heated by gas or electricity. l Ovens – combination of conduction, convection, & radiation. l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Multifunction Equipment l Combination of several pieces of equipment to increase space in production area. Combi-oven – includes convection and/or steam l Tilting skillet – combines range, griddle, kettle, stock pot, & frying pan. l Convection/microwave oven - includes convection and/or microwave l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Production Controls l Quality control – assuring day-in, day-out consistency in each product. l Quantity control – producing exact amount needed. l Controls: Time & Temperature Control l Product Yield l Portion Control l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Energy Use l Direct energy – energy expended to produce & serve menu items. l Indirect energy – energy expended to facilitate functions that use direct energy. © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Energy Conservation ENERGY STAR®: partnership which promotes energy efficiency in buildings & homes. l Energy conservation checklist: l l l l Food Preparation Refrigeration Lighting HVAC Sanitation & water Office & Administration © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire

Energy Management l Should include: Record-keeping system for tracking utility costs & monitoring equipment use. l Employee training l Use of energy efficient equipment l © 2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458 Foodservice Organizations, 5 th edition Spears & Gregoire