FBM - Production Process Planning

PRODUCTION PROCESS
PLANNING
HISTORY
• EVOLVED OVER A PERIOD OF TIME
• THIS TOOK PLACE WHERE
- THERE WAS AN ABUNDANCE OF
LABOUR
- CHEAP RENTAL SPACE
• TASKS WERE DIVIDED INTO “PARTIES”

- SIMILAR TASKS, WITH
NUMEROUS
FOODS, MANY PEOPLE
HISTORY
IN THE LAST 30 YEARS THINGS BEGAN TO
CHANGE
• RESEARCH BY SUPPLIERS
• RISING LABOUR COSTS
• INCREASE OF CATERING COSTS
• RISING RENTAL COSTS
PRODUCTION METHODS
1. CONVENTIONAL METHODS
- Traditional Partie Method

- Production with convenience
foods
Traditional Partie Methods
• Food purchased raw
• Little of convenience food
• Facilities provided for receipt and storage of
goods, the preparation, cooking, holding and
service of food, dishwashing facilities.
• Labor is intermittent – poor utilization of plant
• Poor use of fuel
• Expensive to run – manpower, space, energy
requirements
Raw Food Supplies
Chill/ Frozen
Dry Goods
Store
Food Production Parties
Sauce Roast Fish Larder Soup Vegetable

Pastry
Serve Serve
CONVENTIONAL PRODUCTION WITH
CONVENIENCE FOODS
• CAN BE INTRODUCED INTO A TRADITIONAL KITCHEN
- RANGE FROM PARTIAL TO COMPLETE
- BEST USE CAN ONLY BE SEEN BY A MEANS OF A PLANNED
CATERING
SYSTEM
• BEST IN RELATION TO A SYSTEMS APPROACH THAT THE

OPERATION BE
CONSIDERED AS A WHOLE
• IF INTRODUCED INTO A TRADITIONAL KITCHEN THE EFFECTS

ON
- LABOUR
- EQUIPMENT
- SPACE
- CUSTOMER
CENTRALISED PRODUCTION
METHODS
• SEPERATION OF THE PRODUCTION AND

SERVICE COMPONENTS BY
- PLACE OR TIME
- OR BOTH
• IN BATCHES
• OR PER PORTIONING
• READY TO SERVE STATE OR CHILLED
• BECAME POPULAR IN THE WELFARE
SECTOR
• HAVE NOW BEEN CLOSED DUE TO HIGH
OPERATIONAL COSTS
ADVANTAGES OF CENTRALISED
PRODUCTION
• NO PEAKS AND TROUGHS
• CONCENTRATION OF SKILLED STAFF AT CPU
–
HIGHER PERFORMANCE AND QUALITY.
SATELLITE KITCHENS – NON SKIILED
• BULK PURCHASING REDUCES RAW
MATERIAL
COST AND OVERALL FOOD COST/MEAL
• INTRODUCTION OF THE STORAGE STAGE
IMPROVES EFFICIENCY OF KITCHEN STAFF
AND
EQUIP
DISADVANTAGES OF CENTRALISED
PRODUCTION
• HIGH COST OF CONSTRUCTION
• UNLESS UTILISED PROPERLY COST/MEAL CAN
RISE
• PRODUCTION FAILURES – POWER OUTAGES,
HYGIENE OF FOOD CONTAMINATON CAN
QUICKLY
ESCLATE QUICKLY.
Fresh Food Supplies Frozen Food Supplies
Dry food / chill store Freezer Store
Central Preparation
Blast Chilling to 0 C – 3 C
Chill store Transport to Chill Store

Peripheral units
Reheating to service Reheating to service

requirements requirements
Serve Serve
BASIC PRINCIPLES OF COOK –
FREEZE AND COOK – CHILL SYSTEMS
• All raw food should be of good microbiological quality
• Initial cooking will ensure destruction of vegetative
stages
of any pathogenic micro – organisms present
• Spores – rapid rising of temperature to above 60 C.
( 7C – 60C) restricts growth.
• Cross contamination between raw and cooked food.
Physical separation – Pre-preparation and cooking areas
• Storage and distribution conditions must be strictly
controlled to ensure quality and safety.
• Reheating and service conditions must be strictly adhered
to, to
Quality of Raw Food
1. General storage conditions:
Loss will occur – fresh vegetables prior to cooking
or in water after preparation. Kept under right
temperature for as short as possible.
2. The type of Processing:
Overcooking, over regeneration, poor refrigeration
storage, and delay between re-heating and
consumption all add to vitamin loss and palatability.
Cook –Freeze Production
Full Cooking followed by fast freezing, with
storage at a controlled temp of – 18C. It is
the complete food production process from
the initial raw food to the final service of the
product.
Cook Freeze Production Process
1. Raw food should be purchased against a tight
specification to ensure quality and consistency.
- Laboratory testing of all incoming food. (large
Operations)
- Standard checking procedure
- Inspection of suppliers premises.
- Regular checks on quantity and control
procedures.
2. Food Storage:
- All foods kept under strict temperature control
- Hygienic conditions
- without any cross contamination
- Strict rotations of stock
3. Pre – preparation:
- Includes all preparation of foods prior to
cooking.
- Standard procedure to keep this stage of the
process separate from the next stage
- Restrict all staff handling raw food to this area
4. Cooking:
- Should be done in small batches.
- Internal temperatures to reach 70C.
- Recipes may be adjusted for the length of time
of storage
5. Portioning
- Hot food should be portioned into single or
multi-portioned containers to a depth of 50mm
- kept in a blast freezer
- within 30 minutes after cooking
6. Blast chilling
- 0 C to 3 C
- within 90 minutes of being placed inside the
Freezer
- preserves food quality
- prevents bacteria
7. Chill Freezing:
- shelf life of cooked foods is a maximum of 5
days. Inclusive of production, distribution and
regeneration.
- stored between 0 C to 3 C
- prevents bacterial growth and cross
contamination.
- each container should be clearly marked:
Product name, batch number, production date,
and expiry date. This aids stock rotation.
8. Distribution:
- should only take place in refrigerated or
insulated containers.
- increase in temperature till 5 C is allowed
- after which it should be brought down rapidly
to 0 C to 3 C.
- if temperature rises to 5 C to 10 C. food should
be consumed within 12 hrs
- if temperature exceeds 10 C food needs to be
destroyed.
9. Regeneration:
- must be regenerated within 30 mins after
taking out of chill store.
- food must be reheated to 70 C and held there
for 2 mins
BEVERAGE PRODUCTION METHODS
Beverage includes both alcoholic and non-alcoholic
beverages.
1. Raw beverages:
- these are products that require a higher degree of
preparation (tea, coffee, cocoa)
- usually far away from the service area. OR
included into the facilities of the restaurants and
coffee shops itself.
2. Semi prepared beverages:
- These are beverages that do not need to be
prepared from the raw stage. (cordials, iced tea,
cold coffee, cocktails)
- the preparation may be part of the service
itself
3. Fully prepared beverages:
- Beverages that do not require any preparation
- bottled fruit juices, spirits, bottled aerated
drinks, wines.
- dispensed in front of the customer
THINGS TO KEEP IN MIND FOR BEVERAGE
PRODUCTION
• Keep equipment clean and hyginic

• Check equipment regularly
• operates within the financial limits of the
organization
• good quality raw ingredients

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PRODUCTION PROCESS

• TASKS WERE DIVIDED INTO “PARTIES”

- Traditional Partie Method

Food Production Parties

Sauce Roast Fish Larder Soup Vegetable

• BEST IN RELATION TO A SYSTEMS APPROACH THAT THE

• IF INTRODUCED INTO A TRADITIONAL KITCHEN THE EFFECTS

• SEPERATION OF THE PRODUCTION AND

Dry food / chill store Freezer Store

Chill store Transport to Chill Store

Reheating to service Reheating to service

• Keep equipment clean and hyginic

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