Fbm - Production Process Planning
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Transcript of Fbm - Production Process Planning
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PRODUCTION PROCESS PLANNING
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HISTORY
EVOLVED OVER A PERIOD OF TIME
THIS TOOK PLACE WHERE
-THERE WAS AN ABUNDANCE OFLABOUR
- CHEAP RENTAL SPACE
TASKS WERE DIVIDED INTOPARTIES
- SIMILAR TASKS, WITH NUMEROUS
FOODS, MANY PEOPLE
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HISTORY
IN THE LAST 30 YEARS THINGS BEGAN TO CHANGE
RESEARCH BY SUPPLIERS
RISING LABOUR COSTS INCREASE OF CATERING COSTS
RISING RENTAL COSTS
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PRODUCTION METHODS
1. CONVENTIONAL METHODS
-Traditional Partie Method
- Production with convenience foods
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Traditional Partie Methods
Food purchased raw
Little of convenience food
Facilities provided for receipt and storage of
goods, the preparation, cooking, holding andservice of food, dishwashing facilities.
Labor is intermittent poor utilization of plant
Poor use of fuel
Expensive to run manpower, space, energy
requirements
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Raw Food Supplies
Dry GoodsChill/ Frozen
Store
Food Production Parties
Serve
Sauce Roast Fish Larder Soup Vegetable Pastry
Serve
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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 BECONSIDERED AS A WHOLE
IF INTRODUCED INTO A TRADITIONAL KITCHEN THE EFFECTS ON
- LABOUR
- EQUIPMENT
- SPACE
- CUSTOMER
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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
BETTER WORKING AND SOCIAL HOURS
SCHEDULING DROPS ENERGY CONSUMPTION
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DISADVANTAGES OF CENTRALISED
PRODUCTION
HIGH COST OF CONSTRUCTION
UNLESS UTILISED PROPERLY COST/MEAL CAN RISE
PRODUCTION FAILURES POWER OUTAGES,
HYGIENE OF FOOD CONTAMINATON CAN QUICKLYESCLATE QUICKLY.
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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
Peripheral units
Chill Store
Reheating to service
requirements
Serve
Reheating to service
requirements
Serve
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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 strictlycontrolled to ensure quality and safety.
Reheating and service conditions must be strictly adhered to, to
ensure safety with the temperature of all food being strictly
monitored.
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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 foras short as possible.
2. The type of Processing:
Overcooking, over regeneration, poor refrigeration
storage, and delay between re-heating and consumption alladd to vitamin loss and palatability.
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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.
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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.
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Cook Freeze Production Process
2. Food Storage:
- All foods kept under strict temperature control
- Hygienic conditions
- without any cross contamination- Strict rotations of stock
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Cook Freeze Production Process
3. Pre preparation:
- Includes all preparation of foods prior to
cooking.
- Standard procedure to keep this stage of theprocess separate from the next stage
- Restrict all staff handling raw food to this area
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Cook Freeze Production Process
4. Cooking:
- Should be done in small batches.
- Internal temperatures to reach 70C.
- Recipes may be adjusted for the length of timeof storage
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Cook Freeze Production Process
5. Portioning
- Hot food should be portioned into single or
multi-portioned containers to a depth of50mm
- kept in a blast freezer- within 30 minutes after cooking
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Cook Freeze Production Process
6. Blast chilling
- 0 C to 3 C
- within 90 minutes of being placed inside the
Freezer- preserves food quality
- prevents bacteria
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Cook Freeze Production Process
7. Chill Freezing:
- shelf life of cooked foods is a maximum of5
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.
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Cook Freeze Production Process
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.
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Cook Freeze Production Process
9. Regeneration:
- must be regenerated within 30 mins after taking
out of chill store.
- food must be reheated to 70 C and held therefor 2 mins
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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.
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2. Semi prepared beverages:
-These are beverages that do not need to beprepared from the raw stage. (cordials, iced tea,
cold coffee, cocktails)
- the preparation may be part of the service itself
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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
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THINGS TO KEEP IN MIND FOR BEVERAGE
PRODUCTION
Keep equipment clean and hyginic
Check equipment regularly
operates within the financial limits of theorganization
good quality raw ingredients