The document outlines various food production systems used in the hospitality industry, including conventional, centralized, cook-chill, cook-freeze, sous-vide, and assembly kitchens. Each method offers distinct advantages and disadvantages regarding cost, efficiency, and food quality, with a focus on productivity and safety. The document also emphasizes the importance of managing food safety, quality control, and utilizing modern technologies to optimize production processes.

1. Unit:5 Food production
system
Food production instructor : Ashish Raut
Liberty college
BHM 4th
semester

2. Contents…
1.1 Meaning of food production system
1.2 Generic model of food production systems
1.3 Type/ Method of food production system
• Conventional/ Traditional
• Centralised(commissary)
• Cook-chill
• Cook-freeze
• Sous-vide
• Assembly kitchen(Convenience)
• Call order

3. 1.1 Meaning of food production system
 New production or service systems for food service organizations have developed
in recent years.
Characterized by a separation of production and service of food in time and/or
place, these new systems have been primarily aimed at increasing productivity,
decreasing cost, or strengthening control of operations.
Because food production chefs /managers assume primary responsibility for food
safety and quality regardless of the type of system, complex managerial decisions
are required to develop and implement appropriable food production systems that
production or serve quality food at minimal cost.
The physical, chemical and ln microbiological changes occurring in food throughout
all stages of procurement, production and service must be monitored and
controlled to ensure the. quality and safety of the finished products.
They also focused to use latest technologies, avoid, highly skilled employees,(lack of
available of skilled employees, avoid turnover of employees, ultimately minimize
the food cost by ensuing quality/ hygienic food production)

4. Conti…
Meaning of food production system
food production system is a way to produce the right quantity of food at the
correct standard, for required clientele, on time, using the resources available in
efficient and effective way.
Many operations today are based on the process approach of cooking as
compared to traditional (conventional/ production & service same place) method
of cooking where ‘partie’ or ‘brigade’ system is common.
The process approach concentrates on the specific techniques and processes of
food production.
When we apply this process approach of Food production, system in hospitality
industry we can figure following process/step.

5. Cont.… Stages of the food production process

6. 1.2 Generic model of food production systems

7. 1.3 Types /method of food production system
S.N Method Description
1 Conventional(co
ok serve)
Term used to describe production utilizing mainly fresh foods and traditional
cooking methods.
2 Convenience Methods of production utilizing mainly convenience foods.
3 Call order Method where food is cooked to order either from customer (cafeteria) or from
waiter. Production area are open to customer area.
4 Continuous Method involving production line approach separate where different parts of
production process are/may. (fast food)
5 Centralized Production not directly linked to service. Foods are held and served to different
service areas.
6 Cook-chill Food production storage and regeneration method utilizing principle of low
temperature to control and preserve quality of processed food.
7 Cook-freeze Production, storage and regeneration method utilizing principle of freezing to
control and preserve qualities of processed food.
8 Sous-vide Method of production, storage and regeneration utilizing principle of sealed
vacuum to control and preserve the quality of processed food.
9 Assembly
kitchen
A system based on accepting and incorporating the latest technology in
manufacturing and conservation of food.

8. Conti…
1.3.1 Centralized Food production system
-The central food service system (also known as commissary kitchen, central food
production, or food factory) centralizes food production, and food is transported to
satellites (receiving kitchens) where it is served to customers.
- Mostly, followed by bulk food production catering establishments ( airline catering,
hospital catering, institution catering , industrial)
- Food usually is purchased near the none end of the food processing continuum, and food
preparation is done in the central kitchen, which results in lower food costs (low energy
use, low labor cost, enough working space and modern technology or tools and
equipment, low transportation cost, etc.)
- The centralized food production uses the skilled staff available to prepare and cook in
bulk and the to distribute to finishing kitchens ( satellites)which are smaller, employing
semi skilled and unskilled labour.
- The centralized food production system can be used cook freeze, cook chill and sous
video systems.( Because, these methods have been developed to meet centralized food
production system)

9. Conti…
1.3.2 Why centralized ?
Some special problems faced by the catering industry are follows :
i. Staff ( limited numbers of skilled staff, mobility of labour)
ii. Food ( high cost, wastage)
iii. Equipment( high cost of replacement and maintenance, transport cost )
iv. Energy ( wasteful high cost system)
v. Overheads ( wage increase, payment to insurance)
vi. Space ( space is very costly)
Helps following areas
-Control Food cost, Equipment ( intensively use heavy equipment less in
individual units), Products( consistency and quality control), labour strategy
( employed at regular basis for eg 9 am to 5pm, less burden scheduling)

10. 1.3.2 Advantage and disadvantage of centralized food
production system
Advantages
• Lower food and supply costs
• Ingredient control is improved
• Flexibility in scheduling of food
preparation
• Quality control(HACCP, food
characteristics, nutritional quality)
• Consistency
• Better utilization of production
facility
Disadvantages
• High initial capital investment for
building and equipment.
• More technically skilled employees
are required
• Some jobs may be very monotonous
• Equipment malfunctions can be
significant
• Food safety problems can affect
many customers

11. Conti..
1.3.3 Food flow in centralized food production and service

12. 09/25/2024 12
Conti…
1.4.1 Cook chill
Cook chill & cook freeze are a specialized food production & distribution system that
allows food caterers to take advantage of the longer shelf life of processed food.
Cook chill is a catering system based on the normal preparation, cooking of food followed
by rapid chilling and storage in controlled low temperature conditions after that chilled
food is regeneration in finishing kitchen/ regeneration kitchen.
The main advantage of cook freeze smoothly work in minimum staffs and consistency or
quality production by maintain high standard hygiene and sanitations.
Food cooked in advance in different form & quickly chilled to 3*c ( either blast chilling,
traditionally immersing in a tank of water where cold air circulated around in food).
Bulk food preparation catering followed this system.( hospitals, schools, banqueting and
conference catering )
Food is stored in container, then chilled, storing & reheating/ regeneration. ( special care,
recommended degree temperature to prevent under/ over cooking).
Hygiene & sanitation is most important during whole process cooking, chilling,
transporting , regeneration.

13. 1.4.2 Suitable foods for cook chill process
- Almost most of the foods can be cook chilled
but, catering need to be followed correct
methods:
i.) Meat/ poultry/game ( it should be
cooked, it is not possible to serve under
cook meat)
ii) Fish ( all precooked fish are suitable for
cook)
iii) Egg dishes ( omelets and scrambled egg
common in airlines)
iv.) soups and sauces ( most of chilled
successfully but, high fat and egg based
soups may coagulated during regeneration)
v) Dessert ( all types of sweets
chill well, for hot separate
topping)

14. 09/25/2024
Conti…
1.4.23Cook chill process
14
Dry
store
Cold
store
Vegeta
ble
store
Preparation
/ cooking
fish
Meat
vegetable
sweet
Porti
oning
/
packa
ging
Disp
atchi
ng
Blast
chille
r Chill
store
Regene
ration

15. 09/25/2024 15
Conti…
1.5 Cook freeze
Cook freeze is a production similar to cook chill using blast freezers rather than
blast chiller.
Cooked, portioned, packaged, blast freezer/ frozen quickly -5*c in less than
90min/ 1.5 hr. finally deep freeze in -18*c to – 20*c, dispatching, reheating/
regeneration.
 The main difference between cook freeze & cook chill is the degree of
refrigeration & length of storage life of food.
Regeneration may be done from frozen state or allowed to thaw.
Most food can be stored 2 to 6 months.

16. 09/25/2024 16
Conti…
1.5.1 Cook freeze process

17. 17
Conti..
1.6 Sous vide ( vacuum cooking)
French term, meaning under vacuum
In the mid–1970s, French Chef Georges Pralus, introduced
sous vide cooking to the world.
Food is placed in a plastic pouch or a glass jar and then placed
in a water bath or steam environment for longer than normal
cooking times.
Civilized method without losing any quality of meals.( suitable
for fruits and green vegetables no oxidation or discolored e.g.
pear in red wine, syrup etc.)
Vacuum packed food is partially or fully cooked, shelf life, up
to 21 days
refrigerated.
If partially cooked food is heated in steamer or bain- marie.
Finish by searing, grilling, broiling the food to add a crispy,
golden exterior layer.
09/25/2024

18. 1.6.1 Process of sous vide
i) Raw food commodities/ Raw materials
ii) Individual portion ( Under vacuum )
iii) Cooking (Cooked in sous vide cooker or
stem or temperature controlled water)
iv) Rapid chilling ( ice water bath or chiller)
v) Labelled and storing in refrigerator or
chiller storage.
vi) Dispatching
vii) Regeneration or reheating
viii)Serving

19. 09/25/2024 19
Conti…
1.6.2 Advantage and disadvantage of sous vide / vacuum
cooking
 The food does not loos its natural juices hence retaining the natural flavors and
nutrients.
 Healthy due to use of less fat, spices.
 Vegetables those are soft but not discolored and disintegrated.
 Lack of shrinkage of food commodities.
 Simple use and uniform and consistent results.
 Maximizes advance preparation and facilitates work at peak times.
 Low power consumption compared to ovens.
 Different dishes can be regenerated simultaneously without mixing flavors.

20. 1.7 Conventional food production system
The conventional food service system is the type most establishments have traditionally
used in the parties system.( Use fresh food commodities and traditional cooking methods)
Foods are purchased for an individual operation in various stages of preparation, but all
production is completed and foods are served on the same premises.
In Conventional production, foods are held hot or chilled, as appropriate for the menu
item, and served as soon as possible.
Foods with varying degrees of processing are brought into the system and prepared for
service in the food production sub-system.
Hot-holding conditions is affected by temperature, humidity and length of holding time,
all of which can adversely affect its nutritional and sensory quality and must be
considered when scheduling food production.
Some food are merely purchased and held chilled before service, such as milk or butter
patties, whereas other menu items are produced in the system from raw foods and held
either heated or chilled until time of service.

21. 1.7.1 Food flow chart of conventional food production and service

22. 1.7.2 Advantage and disadvantage of Conventional food
production system
Advantages
• Flexibility in menu items
• Food is served soon after
preparation
• Less cost in modern technologies.
• Traditional standardized recipes
can be used
Disadvantages
• Higher food costs
• Less Food safety
• Problem in consistency
• More labor need

23. 1.7.3 Process of conventional food production
• Group Discussion
• Collect the idea from students
• Finalized the process
-Raw material
-Storing
-Preparation/ cooking
-Holding or chilled
- Service

24. 1.8 Assembly food production system
• The development of assembly production systems - also referred to as
convenience food systems or systems using minimal cooking concepts came
about primarily because of the availability of foods that are ready to serve or
that require little or no processing in the food production operation prior to
service.
• Food products are brought into the system with a maximum degree of
processing.
• In assembly-serve foodservice systems, food is purchased at the middle to
complete end of the food processing continuum. The purchased food is stored
either frozen or chilled for later use. It is then portioned, reheated, and served
to customers.
• Currently, The assembly kitchen incorporates the latest technological
developments the manufacturing and conservation of food products.( high
skilled, high quality convenience food, industrial types focus)

25. 1.8.1 Food flow in
assembly
food production
& service system

26. 1.8.2 Advantages and disadvantages of Assembly- serve food
production System.
• Advantages
- Lower labor costs
- Fast service
- Less burden in kitchen
• Disadvantages
- Perceived loss of quality
- Menu variety may be limited

27. 1.8.3 Assembly food production
process
i. Preprocessed food received
ii. Storing( store frozen or chilled)
iii. Portioning
iv. Heating
v. Serving

28. 1.9 Call order production
Method where food is cooked to order either from customer
(cafeteria) or from waiter. Production area are open to customer area.
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29. Assignment 2: Research, about call order food production system and
identify its similarities & difference with other food production
systems similarly, enlist its process ( call order).
Thank you!!!