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

1. Kitchen Design workshop
September 11th, 2013

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. www.fcsi.org

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. 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. 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. 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. 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. 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. What can be done to reduce power
consumption in a foodservice
operation?

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. 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. 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. # 2 – Exhaust fan management
systems

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. # 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. # 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. # 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. # 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. 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. # 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. 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. # 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. 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. 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. 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. 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. 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. Thank you