chapter 6 · food production food production is the preparation of menu items in the needed...

Chapter 6

Food Production

Foodservice Organizations, 5th edition

Spears & Gregoire

©2004 Pearson Education, Inc.

Upper Saddle River, New Jersey 07458

Functional Subsystem:

Food Production

� Food production is the preparation of menu items in the needed quantity & with the desired quality.

� Quantity – Distinguishes foodservices production from home or family food preparation.

� Quality – Aesthetic, nutritional, & microbiological safety aspects of a food product.


Spears & Gregoire



Production Subsystem Objectives

� Primary: Transform human, material, facility, & operational resources into outputs.

� Secondary:� Product/service characteristics

� Process characteristics

� Product/service quality

� Efficiency:

� Effective employee relations & cost control of labor

� Cost control of materials

� Cost control of facility use

� Customer service:

� Produce quantities to meet expected demand

� Meet delivery date for products or services


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Production Decisions

� Includes forecasting, planning, &

production scheduling.

� Synthesis of quantity, quality, & cost

objectives.

� Product characteristics

� Production process characteristics

� Establishment of standards of quality


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Production Forecasting

� Primary result of forecasting should be

customer satisfaction.

� Production Demand

� Overproduction – Production of more food

than is needed for service.

� Underproduction – Production of less food

than is needed for service


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� Quantity Demand

� Estimate number of customers or the

number of servings.

� Essential to use suitable forecasting model.

� Examples:

� Historical records

� Intuition

� Complex models requiring large amounts of data


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� Historical Records

� Effective production records should include:

� Date & day of the week

� Meal or hour of service

� Notation of special event, holiday, & weather conditions

� Food items prepared

� Quantity of each item prepared

� Quantity of each item served

� Provide fundamental base for forecasting quantities

when the same meal or menu item is repeated.


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Forecasting Models

� Criteria for a Model:� 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.


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Types of Models

�Most common model categories:

� Time series

� Casual

� Subjective

� Trends & seasonality in the data must be

considered.


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Time Series Model

� Assumption that actual occurrences

follow an identifiable pattern over time.

� Suitable for short-term forecasts.

� Frequent time series models:

� Moving average forecasting model

� Exponential smoothing forecasting model


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Moving Average Forecasting Model

� First point: average of number of portions

sold for the last five or more times the menu

item was offered.

� Second point: average of dropping the first

number & adding the most recent number of

portions sold to the bottom of the list.

� Continue process for all data.


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Moving Average Forecasting Model


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Exponential Smoothing Forecasting

Model

� 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.

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Casual Model

� Assumption that an identifiable

relationship exists between the item

being forecast & other factors.

� High costs for development & use.

� Popular for medium- & long-term

forecasts.


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Regression Analysis Forecasting

Models

�Most commonly adapted.

� Includes:

� Dependent variables – items being forecast.

� Independent variables – factors determining

the value of the dependent variables.

� Requires a history of data to permit

plotting over time.


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Subjective Model

� Used when relevant data is scarce or

patterns & relationships between data do

not tend to persist over time.

� Delphi technique

� Market research

� Panel consensus

� Visionary forecast

� Historical analogy


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Production Scheduling

� Time sequencing of events required to produce a meal.

� Planning stage:

� 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:

� Supervisors prepare a production schedule.

� Items are assigned to specific employees.


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Production Schedule

� Should include:� 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


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Production Meetings

� Should be held daily with employees in

the production unit.

� Employees encouraged to discuss the

effectiveness of the schedule.

� Free discussion of work loads.

� Conclude with discussion of the

production schedule for the following

three meals.


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Ingredient Control

� Begins with purchasing, receiving, & storage of foods.

� Continues through forecasting & production.

� Ingredient assembly – area designed for measuring ingredients.

� Standardized recipes – provides assurance that standards of quality will be consistently maintained.


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Advantages of Centralized

Ingredient Assembly

� Contributes to the cost reduction &

quality improvement.

� Redirection of cooks’ skills away from

collecting, assembling, & measuring

ingredients to production, garnishing, &

portion control.

�More efficient use of labor.


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Centralized Ingredient Control

� Control of unused portions is facilitated

because storage is located centrally

rather than in various work units.

� Ability to combine tasks for two or more

recipes using similar ingredients.


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Function of the Ingredient Room

� Primary function is to coordinate

assembly, pre-preparation, measuring, &

weighing of the ingredients.

� Availability of appropriate equipment will

help determine the activities to be

performed.


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Ingredient Room Organization

� Should be located between the storage

& production areas.

� Necessary equipment includes:

� Refrigeration

� Water supply

� Trucks or carts for assembly & delivery

� Worktable or counter

� Scales


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Ingredient Room Staffing

� Employees must be:

� Literate

� Able to do simple arithmetic

� Familiar with storage facilities

� Responsible for receiving, storage, &

ingredient assembly.


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Ingredient Room Staffing

� Ingredient assembly personnel considerations:� 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


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Future of Ingredient Rooms

� Centralized or food factories are being

used for procurement & production.

� Prepared menu items are distributed to

several remote areas for final

preparation.


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Recipe

� Formula by which weighed & measured ingredients are combined in a specific procedure to meet predetermined standards.

�Written communication tool that passes information from the foodservice manager to the ingredient room & production employees.

� Quality & quantity control tool.


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Recipes

� Recipes include:� 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.


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Format

� All recipes in an operation should be in

the same format.

� Common large quantity formats:

� Block format

� Complete block format

� Modified block format


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Block Format

� Ingredients listed on left side of recipes.

� Procedures directly opposite ingredients

on right side.


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Complete Block Format

� Horizontal lines separate each group of

ingredients with procedures.

� Vertical lines separate the ingredient,

amount, & procedure columns.


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Modified Block Format

�Most common

� Horizontal lines separate the required

ingredients for each procedure.


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Format

� Additional information often added at

bottom or on back:

� Approximate nutritive values per portion

� Variations on the recipe

� Special serving instructions

� Storage requirements before & after service


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Format

� Recipes should be in large print easily

readable from 18-20 inches.

� Recipe name should be in bold letters.

�Major categories (breads, meat, salad,

etc.) may be color coded to make

identification easier.

� KEEP BACKUP OF RECIPES!!!


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Standardization

� Ideal to have recipes that consistently

deliver the same quantity & quality

product when followed precisely.

� Recipe standardization – process of

tailoring a recipe to suit a particular

purpose in a specific foodservice

operation.

� Requires repeated testing.


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Justification

� Advantages for using standardized

recipes:

� Promote uniform quality of menu items.

� Promote uniform quantity of menu items.

� Encourage uniformity of menu items.

� Increase productivity of cooks.

� Increase managerial productivity.

� Save money by controlling overproduction.


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Justification

� Advantages (cont.):

� Save money by controlling inventory levels.

� Simplify menu item costing.

� Simplify training of cooks.

� Introduce a feeling of job satisfaction.

� Reduce anxiety of customers with special

dietary needs.


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Three Phases of Recipe

Standardization

� Standardized recipes:

� Developed for use by a foodservice

operation.

� Found to produce consistent results & yield

each time prepared.


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Three Phases of Recipe

Standardization


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Recipe Verification

� Review components of the recipe� Recipe title

� Recipe category

� Ingredients

�Weight/measure for each ingredient

� Preparation instructions

� Cooking temperature & time

� Portion size

� Recipe yield

� Equipment to be used


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Recipe Verification

�Make the recipe

� Verify the recipe yield

� Record changes to the recipe


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Product Evaluation

� Informal Evaluation:

� Visual appearance

� Flavor

� Ability to obtain ingredients

� Cost per serving

� Labor time

� Availability of equipment

� Employee skill


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Product Evaluation

� Formal Evaluation

� 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.


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Quantity Adjustment

�Methods include:

� Factor method

� Percentage method

� Direct reading measurement tables

� Computer software also available


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Factor Method

� Change ingredient amounts to whole

numbers & decimals.

� Divide desired yield by the recipe yield to

determine the conversion factor.

�Multiply all recipe ingredients by the

conversion factor.


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Factor Method

� Reconvert decimal unit back into pounds

& ounces or quarts & cups.

� Round off amounts to quantities simple

to weigh or measure.

� Check math for possible errors.


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Percentage Method

� Convert all ingredients from measure or pounds & ounces to tenths of a pound.

� Total the weight of ingredients in a recipe after each ingredient has been converted to weight in the edible portion.

� Calculate the percentage of each ingredient in the recipe in relation the total weight.

� Check the ratio of ingredients.


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Percentage Method

� Establish the weight needed to provide

the desired number of servings.

� Add handling loss to the weight needed.

�Multiply each ingredient percentage

number by the total weight to give the

exact amount of each ingredient needed.

� Convert to pounds & ounces or to

measures.


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Direct Reading Measurement

Tables

� Quick to use & require no mathematical

calculations.

� Used to adjust weight & volume of

ingredients in recipes that are divisible

by 25.


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Adapting Home-Size Recipes

� Special considerations are necessary:

� Know exactly what ingredients are used & in

what quantity.

� Make the recipe in original home-size

quantity.

� Evaluate the product for acceptability.

� Proceed in incremental stages in expanding

the recipe.


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Adapting Home-Size Recipes

� Special considerations are necessary:

� Determine handling or cooking losses (5%-

8% loss is typical).

� Check ingredient proportion against a

standard large quantity recipe.

� Evaluate products using taste panels.


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Quantity Food Production

� Involves:

� Control of ingredients

� Production methods

� Quality of food

� Labor productivity

� Energy consumption.

� Sweet Spot – point of best value at

lowest cost.


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Objectives of Food Production

� Primary reasons to cook food:

� Destruction of harmful microorganisms

� Increased digestibility

� Change & enhancement of flavor, form,

color, texture, & aroma


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Heat Transfer

� Conduction – the transfer of heat

through direct contact from one object to

another.

� Convection – distribution of heat by the

movement of liquid or vapor.


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Heat Transfer

� Radiation – generation of heat energy

by wave action within an object.

� Induction – use of electrical fields to

excite the molecules of metal cooking

surfaces.


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Moist Heat

� Use of water or steam for the cooking process.

� 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.


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Dry Heat

� Use of dry air, hot metal, radiation, or a minimum amount of hot fat for the cooking process.

� Includes:

� Broilers – heat source 3”-6” from food.

� Deep Fat Fryers – food immersed in tank of oil heated by gas or electricity.

� Ovens – combination of conduction, convection, & radiation.


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Multifunction Equipment

� Combination of several pieces of

equipment to increase space in

production area.

� Combi-oven – includes convection and/or

steam

� Tilting skillet – combines range, griddle,

kettle, stock pot, & frying pan.

� Convection/microwave oven - includes

convection and/or microwave


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Production Controls

� Quality control – assuring day-in, day-out

consistency in each product.

� Quantity control – producing exact

amount needed.

� Controls:

� Time & Temperature Control

� Product Yield

� Portion Control


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Energy Use

� Direct energy – energy expended to

produce & serve menu items.

� Indirect energy – energy expended to

facilitate functions that use direct energy.


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Energy Conservation

� ENERGY STAR®: partnership which promotes

energy efficiency in buildings & homes.

� Energy conservation checklist:

� Food Preparation

� Refrigeration

� Lighting

� HVAC

� Sanitation & water

� Office & Administration


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Energy Management

� Should include:

� Record-keeping system for tracking utility

costs & monitoring equipment use.

� Employee training

� Use of energy efficient equipment

chapter 6 · food production food production is the preparation of menu items in the needed...

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