Kitchenology: Tales of Transformation and Efficient and Effective Operations

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Kitchenology: Tales of Transformation and Efficient and Effective Operations Kitchenologist: Mark Finck Download Today s Handouts: www.fishnick.

1 Kitchenology: Tales of Transformation and Efficient and Effective Operations Kitchenologist: Mark Finck Download Today s Handouts: Back-ground Started in QSR as Crew member to Swing manager A decade with Blodgett Oven Co. engineering and developing Ovens Deck, Convection, Combi, Conveyor Started Development Center for Welbuilt known today as Manitowoc Tech Center. Ten years inventing and developing appliances for the industry World wide engineer for Burger King responsible for new cooking platform, ventilation and new restaurant design Independent Consultant Kitchenologist Food Service Technology Center developing and applying appliance energy test methods, and Educating training and information Outreach 1

2 Where is the equipment Information? Han Solo? Heh, I just opened up a new restaurant it s called Light Speed Pizza Restaurateur! One Week Later Yeah, I m still open but, damn! This restaurant business is hard! 2

3 Back ground on a development project I was lead engineer for the development of the Burger King batch broiler This required me to be the first response for appliance service for the test restaurant during development testing. Developed a service repair kit with mfg. for restaurant level service parts on site parts kit. Required service company embrace to use OEM parts on site. Warrantee issues Travel Path of a Food Menu Item From Back of house delivery and storage Food handling form prep to production line Production line process Cooking to order Cooking batch to stage or hold Finishing, plating or assembly of sandwich Finish staging (holding) completing table order Fry In restaurant Fry thermal path Walk in Vertical Frz Frz cook out of fryer Into Hold 2:00 holding 5:00 holding 8:00 consumer 3

Diagnose the current process Take a look at the

to customer Establish the consumer deliverables

cooking time match the speed of service objectives

process deliverable Whopper from Burger King Flame

4 Diagnose the current process Take a look at the complete process Building a Whopper from the start to customer Establish the consumer deliverables Focus on the cooking and holding equipment Can the cooking time match the speed of service objectives Staging the food with QC to align with the total process deliverable Whopper from Burger King Flame Broiled Burger Continuous Chain Broiler with bun toasting 4

Cooking with Fire The Ultimate Risk of restaurant

Fuel to BURN Broiler Learnings The meat cook time and

toasted (heated then cooled) waiting for meat.

Separate FIFO Not controlled, Meat damage broiling due

5 Cooking with Fire The Ultimate Risk of restaurant operations Behind the Door! Fuel to BURN Broiler Learnings The meat cook time and Bun toast times were not aligned result buns were toasted (heated then cooled) waiting for meat. Steamer was buffer zone to stage meat and bun assembly. Separate FIFO Not controlled, Meat damage broiling due to handling and Bun toasting Both meat and bun lost temperature, wet from meat juices and steam water 5

6 FSTC Lab testing Establishing the benchmark of current system design. New design requirement: reduce cost to operate Flexible continues cooking Two conveyor chains What If? The cooking platform was a Batch process? What would a batch be? 9 Whoppers 12 burgers The Batch size was determined, how to handle a batch, the transport the pan size 6

7 Design Simple tool supplied with broiler resolved problem Broiler fit through door way at installation Less parts to clean. Parts designed to fit sink for cleaning 7

8 Broiler Annual Operating Costs* $6,000 $5,000 $4,000 $3,000 $2,000 $1,000 $0 Standard Conveyor Broiler Flexible Batch Broiler FBB with Catalyst *Based on $1.00/therm Servicing New Design How do you support a New design Train service techs Operational training Parts, how do you have the parts available Reliability, Broiler down = Fry King How do you get the restaurant to invest Be the first take a risk of new appliance Change the way the system has operated Reduced ventilation = lower operation cost Fundamentals of Commercial Kitchen Ventilation Package Air Handler Dedicated Kitchen Makeup Air Unit Exhaust Fan 3000 cfm 6000 cfm 3000 cfm 8

Broiler Ventilation New design reduced the hood exhaust rates http://www.fishnick.

9 Exhaust air volume is expressed in Cubic Feet/Minute (CFM) 1 cfm = 1 cubic foot per minute 1 cubic foot is about the size of a basketball The hood eats a lot of basketballs! Broiler Ventilation New design reduced the hood exhaust rates In this test setup, the 4 way diffusers are blowing air directly at the hood 9

10 Watch what happens when air blows on the front of the hood Watch how well the hood works when the air is not blowing directly on it Two diffuser(s) pointing air away from hood 10

11 Questions Changing a Broiling platform? Break Kitchens are moving from: Back of House Middle of House kitchens Kitchens are moving to customer view Smaller Kitchen Space Display cooking Cooking with Fire still active and part of the show Solid fuel Wood part of the show and flavor 11

12 Common Cookline Back of House Kitchen 20-feet Cookline Transformation 20-feet Induction Hot Top, Broiler with lid, Two sided flat griddle, Fryer advancements, combi oven, advanced steamer, advanced cook ware Induction appliances 12

Cooking Energy Efficiency (%) 50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% Standard

13 Can the Pot Make a Difference? Fins Improve Heat Transfer Can Range Efficiency Be Improved? Cooking Energy Efficiency (%) 50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% Standard (Control) Pot Prototype Pot A /Eneron_Pot_Testing.pdf Combi-Ovens have menu flexibility 13

Combi-Oven Continue to gain market share

14 Combi-Oven Continue to gain market share more manufactures We are continuing to test new models and new manufactures Controls are computers! The memory of recipes are increasing complexity to operate Service information being part of the memory Water supply Quality requirements are warranty questions (reverse osmosis) Create the water mineral balance water recipe Cleaning cycle offers sale feature 21 inches Water-Recipe 14

thought the single load volume of cook would not match product delivery More and more units are being used and new sizes

15 High Temperature Deck The trend for Pizza continues to grow with thin crust cooking at 800F in dome radiant ovens Accelerated Ovens Accelerated Ovens Combination of energy Ovens High velocity Air, Micro wave energy, and Radiant heat Once thought the single load volume of cook would not match product delivery More and more units are being used and new sizes smaller are being introduced. Pizza stones or decks are allowing for more acceptance as Pizza oven. Small foot print with flexible cooking 15

Boiler based steamer Servicing Innovative Equipment Discover how state of the art technology is turning the kitchen of today into the kitchen of tomorrow by optimizing:

be smaller, faster, more flexible and more efficient. Operations = Service Problem How many times is the equipment problem a operations problem?

16 Boiler based steamer Servicing Innovative Equipment Discover how state of the art technology is turning the kitchen of today into the kitchen of tomorrow by optimizing: efficiency, functionality and performance while reducing the overall footprint Tomorrow s kitchen will take advantage of new technical innovations in foodservice equipment to be smaller, faster, more flexible and more efficient. Operations = Service Problem How many times is the equipment problem a operations problem? Phone conversation = Service call! Operations failure to clean = function problem Parts removed for cleaning not reassembled correctly = service call Communication can be a key to fixing the service problem 16

17 To the engineer, the glass is twice as big as it needs to be. Getting the information from the end user of the service problem, is a PROBLEM! Efficiency How is it measured 17

18 ENERGY STAR Fryer Advantage Energy site audits Direct Customer Support Energy Surveys and Design Consultation On-site Energy Monitoring Gather data necessary to evaluate and validate energy use and performance 18

19 How do you collect Data? Water Meters, Electric Transducers and Data Loggers Steamer Field Testing Data the numbers What do the numbers mean? Make the data usable for the project Daily profile of Plug-Load Appliances $2260 $2934 $106 $231 19

Interactive exercise UCSF Children s Hospital Case study Review of site (Handout) Equipment for example: Stacked Convection Ovens Discuss the Baseline energy

Interactive exercise Life Cycle Cost Calculation (computer interaction) Fishnick.

20 Interactive exercise UCSF Children s Hospital Case study Review of site (Handout) Equipment for example: Stacked Convection Ovens Discuss the Baseline energy collection requirements Instrument installation Instrument installation Replacement appliances Instrument installation Instrument installation Savings review Interactive exercise Life Cycle Cost Calculation (computer interaction) Fishnick.com Appliance test results Rebate list Cost calculator exerciser Review results from Life Cycle cost to the field study Appliance Testing Laboratory Standardized tests generate comparable performance data, allowing operators to make an informed purchasing decisions! 20

21 Rebate List Questions Visit the FSTC Booth at your show floor 21

Water (Sanitation) 3 Install High Pressure,

face or body or a measured flow rate above 1.

22 Water (Sanitation) 3 Install High Pressure, Low Volume Pre Rinse Sprayers! High Flow Sprayers Identified by: Shower spray pattern, no flow rate (gpm) marking on face or body or a measured flow rate above 1.2 gpm. dex.php?vid=e17 22

23 Air (Ventilation) Air (HVAC) Use & Maintain Programmable Thermostats Set points Occupied Cooling: 73 F 76 F Occupied Heating: 68 F Unoccupied Cooling: 85 F Unoccupied Heating: 55 F 23

Demand Control Ventilation What, When and Where?

Demand Control Ventilation What, When and Where? Presented by: Todd Bell Sr. Energy Analyst Fisher-Nickel Inc. Rich Swierczyna Sr. Engineer Fisher-Nickel Inc. The Food Service Technology Center (FSTC)