Kitchen Design Workshop - Brian Lennox


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Presented at the Clubs+ Chefs Management Summit Sept 2013, presented by Brian Lennox of Universal Foodservice Designs.

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Kitchen Design Workshop - Brian Lennox

  1. 1. Kitchen Design workshop September 11th, 2013
  2. 2. Introduction – Brian J. Lennox FCSI • Foodservice & On premise Laundry Design Consultant • 27 years in the Foodservice industry completing Certification in commercial refrigeration, Small business management, AutoCAD , Freelance journalism. • Professional member of the FCSI – Foodservice consultants Society International.
  3. 3. Design brief – what is required? As part of any design service – communication is a must between all parties to determine; o Anticipated (future) numbers the kitchen will be catering for as this will determine size of preparation, cold stores, plating areas, cooking line(s) and ware washing operations. o Bulk raw produce delivery quantities and times o Waste management requirements (I.E. recycling, compaction, crushing processes) o Patron demographic – will determine portion sizing requirements, menu specifics and spend per patient o Specific menu requirements - what will the menu theme be or influenced by (Asian, Thai, Grill and fried) o Preferred method of production (cook fresh, cook chill or a combination of both) o Preference on the employment of Energy Saving Devices being used and the reduction of power consumption o Staff numbers o Requirements and desire to adhere to State Food Safety Requirements and HACCP best practices o Preference for foodservice production equipment flexibility
  4. 4. Design brief – what is required? o Where does the foodservice operation want to be in 5 years time???? o What are the KPI’s that need to be achieved? (e.g. 20% increase in sales, 20% reduction in maintenance and service costs) o How will this impact on the future design? o Can services be added for future expansion down the track? o Services to double stack combi ovens, add in additional refrigeration, enlarge the dishwashing operation increase speed of service. o Services (utilities) will never be as cheap as they are now to install. o To answer these questions the Club must understand * Demographic requirements * Staff capabilities * Capital funds available * Have a business plan in place
  5. 5. Work flows Key work flow features; - A defined work flow should be allowed for - Bulk stores (both cold and dry should preferably be located close to each other) - Cross over of work spaces should not be designed into the kitchen space
  6. 6. Why is power consumption such an issue for foodservice operations today? Power bills to surge, consumers warned Fri Mar 19, 2010 1:29am AEDT – ABC news Australian consumers are being warned to brace for a surge in electricity prices after New South Wales announced a 30 per cent increase over the next three years. Western Australia moved last year, announcing a 25 per cent hike. The managing director of International Energy Consultants, John Morris, says consumers in other states (such as Victoria) can expect similar price hikes. "There'll be variations from state to state, maybe plus or minus 5 or 10 per cent.“
  7. 7. Victoria facing the largest electricity price hike under ETS • Posted Tue Oct 6, 2009 8:17am AEDT – ABC news Internal briefing documents written on behalf of the Treasurer John Lenders, in April, warn Victoria faces the biggest increases in electricity prices, under the government's proposed scheme. They say the state's industry sector may not be "effectively compensated" under the plan, and that would make it harder to attract businesses to Victoria. The documents estimate Victoria's average household gas and power bill would jump by about $7.00 per week, under the ETS.
  8. 8. POWER CONSUMPTION AND THE FOODSERVICE OPERATION Historically, foodservice operations in an Club operations have been one of the biggest areas where power is consumed.
  9. 9. What can be done to reduce power consumption in a foodservice operation?
  10. 10. Ways to reduce power consumption in a foodservice operation # 1. Using Gas fired cooking equipment over electrically fired equipment. Equipment such as gas Combi ovens, Kettles, Bratt pans, Fryers, Salamanders, Cook tops and Ranges can all work successfully off gas.
  11. 11. Combi ovens are a prime example of having cost savings in Australia when gas is used over electric. • Gas ovens whilst having an approximate 5% to 10% disadvantage on the capital purchase price when compared with electric ovens, can save between $4,000.00 & $4,500.00 per annum. (Based on a 10 tray oven and based on town gas usage NOT LPG).
  12. 12. Ways to reduce power consumption in a foodservice operation • The following brands all have gas combi ovens are part of their range; • Goldstein, Electrolux, Rational, Convotherm, Fagor, Zanus si, Baron & Houno • Note: To make the noted savings on a gas Combi oven you’ll need the gas oven to run on town gas NOT LPG gas. No cost savings are made when using a gas oven on LPG. • The correct gas pressure needs to be in place for the oven to work correctly.
  13. 13. # 2 – Exhaust fan management systems
  14. 14. # 2 – Exhaust fan management systems • Advantages of a Exhaust fan management system • Identifies, the current status of the cooking equipment being either off/on standby/cooking mode. • Adjusts flow rates of the exhaust hood to suit equipment operational mode • Can be reprogrammed to suit changes in the cooking line. • Continually regulates not only the exhaust flow but also the pressure required. By operating a variable pressure and flow rate the exhaust fans do not work as hard and power consumption is reduced by upwards of 40%.
  15. 15. # 3 – Cold store door closers • Major energy loss occurs in a foodservice operation when the cool room or freezer door is left open. • Can cause the cold room to ice up and not maintain temperature. • Heat loss from the cold room makes the refrigeration plant run longer drawing more power. • Cool room door closers are an inexpensive product that ensures that the cold room’s door is closed correctly.
  16. 16. # 4 – Heat recovery systems – or “free hot water from your refrigeration plant” • Heat recovery system use the discharged heat from your refrigeration system to preheat water for your foodservice operation. • The amount of hot water generated will depend on the size of the refrigeration systems at your facility and the amount of time that it operates for. • The system will heat approximately 315 litres, raising the water temperature by 30 degrees over a twelve hour period.
  17. 17. # 5 – Electronic expansion valves • Inside every cool room and freezer is a F.D.C and inside that is an item called a TXV. TXV’s are a mechanical expansion valve that regulates the flow of refrigerant. Recently electronic expansion valves have been introduced into the market. These valves are faster and more accurate resulting in improved system performance which can significantly reduce energy input. Energy reductions can be as much as 20%
  18. 18. # 6 - Better refrigeration plant Efficient refrigeration plant and management practices will see power consumption reduced. Items to consider; 1. Inverter technology on packaged systems 2. Digital scroll refrigeration 3. Masta Cella controls 4. Rack refrigeration 5. Hydrocarbon refrigerant systems 6. Maintain your refrigeration plant.
  19. 19. Refrigeration plant must be maintained o Refrigeration plant should be located in a well ventilated area with service access, labelled with what it running and what refrigerant it is using. o Preferably, refrigeration plant should be located in a dedicated plant area and service on a quarterly basis.
  20. 20. # 7 – Dishwashers * Power, water, chemicals, space and labour costs can all be reduced significantly with the right dishwashing system. * Dishwashing and glasswasher systems can now be procured with in built heat exchangers, reduced water and chemical consumption and operate on cold water to reduce power.
  21. 21. Glass washers Glass washers are now available that only use only 1.9 litres of water per cycle. Compared to older machines that used 3.5 litres and even upwards of 8 litres of water on older wash and dump machines. Reduction in water usage will also reduce chemical usage.
  22. 22. # 8 - Equipment flexibility • Procure equipment that can be multi tasked. Combi ovens Pressure bratt pans/Multi function cookers Blast chilling systems Mixer kettles Also assists in meeting the changing demographic trends of foodservice.
  23. 23. Item for thought – Ewater technology • This product DOES NOT reduce power but instead saves chemical consumption. • ROX Water combines tested and confirmed science with simple technology to deliver cleaning and sanitizing solutions that handle even the most critical and demanding situations. Many hospitals and aged care centres already rely on ROX Water to control infection and eradicate bacteria, viruses, mould, and pathogens of all kinds from just about any surface in their facilities. • ROX Water combines tap water, a salt solution, and a small electrical current in a process known as electrolysis. When two metal strips, respectively called a cathode and an anode, are placed into a dilute saltwater solution, the saltwater molecules begin to divide themselves into positive and negative ions. The result? Two effective, yet safe, solutions – alkaline cleaning water and acidic sanitizing water.
  24. 24. Item for thought – Ewater technology Applications • Disinfects all food contact surfaces and equipment • Cleans, sanitizes, and deodorizes rooms • Clean vegetables and fruit items without chemicals • Extends the life of cut flowers by eliminating spoilage organisms
  25. 25. Item for thought # 2 Induction Cooking Induction cooking offers The operator the ability to use 95% of the heat source. Compared with approximately 60% for gas burners it throws less heat into the kitchen, requires a smaller exhaust system, smaller make up air system and when not in use does not work.
  26. 26. Clubs that have employed some of these ideas • St.George Rowing Club – employed ewater technology • South Juniors – Blast chilling and low temperature cooking overnight • Cabramatta Leagues Club – Digital scroll refrigeration and Electronic expansion valve technology • Maitland City Bowling Club – Rack refrigeration and low velocity exhaust hood • Davistown RSL – Gas combi oven and low velocity exhaust hood • Camden Valley Country Club – Multi function cooking equipment and low velocity exhaust hoods
  27. 27. CONCLUSION – what needs to be done if your planning to develop a foodservice operation • DO YOUR HOMEWORK • Understand what capital is available, what you patron wants, where you want to take your foodservice operation (business plan), be open to new ideas. Look at your power consumption now and review how it can be lowered as this can help your bottom line. * Cost increases will impact on all of us. * Equipment and systems are in place that will assist in reducing operating costs. * These items need to be investigated and included in any new refurbishment or development plans * These items will have a capital cost impact but also have a rate of return that should not be overlooked.
  28. 28. Thank you