1. Chapter 6
Food Production

2. Functional Subsystem: Food Production
Food production is the preparation of menu items in the needed quantity & with the desired quality.
Quantity – Distinguishes foodservices production from home or family food preparation.
Quality – Aesthetic, nutritional, & microbiological safety aspects of a food product.
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3. Production Subsystem Objectives
Primary: Transform human, material, facility, & operational resources into outputs.
Secondary:
Product/service characteristics
Process characteristics
Product/service quality
Efficiency:
Effective employee relations & cost control of labor
Cost control of materials
Cost control of facility use
Customer service:
Produce quantities to meet expected demand
Meet delivery date for products or services
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4. Production Decisions
Includes forecasting, planning, & production scheduling.
Synthesis of quantity, quality, & cost objectives.
Product characteristics
Production process characteristics
Establishment of standards of quality
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5. Production Forecasting
Primary result of forecasting should be customer satisfaction.
Production Demand
Overproduction – Production of more food than is needed for service.
Underproduction – Production of less food than is needed for service
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6. Production Forecasting
Quantity Demand
Estimate number of customers or the number of servings.
Essential to use suitable forecasting model.
Examples:
Historical records
Intuition
Complex models requiring large amounts of data
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7. Production Forecasting
Historical Records
Effective production records should include:
Date & day of the week
Meal or hour of service
Notation of special event, holiday, & weather conditions
Food items prepared
Quantity of each item prepared
Quantity of each item served
Provide fundamental base for forecasting quantities when the same meal or menu item is repeated.
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8. Forecasting Models Criteria for a Model:
Cost – expenses of both development & operation.
Required accuracy – accuracy of its predictions of future occurrences.
Relevancy of past data – relationship of past & future data.
Forecasting lead time – length of time into future the forecasts are made.
Underlying pattern of behavior – actual occurrences follow some known pattern.
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9. Types of Models Most common model categories:
Time series
Casual
Subjective
Trends & seasonality in the data must be considered.
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10. Time Series Model
Assumption that actual occurrences follow an identifiable pattern over time.
Suitable for short-term forecasts.
Frequent time series models:
Moving average forecasting model
Exponential smoothing forecasting model
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11. Moving Average Forecasting Model
First point: average of number of portions sold for the last five or more times the menu item was offered.
Second point: average of dropping the first number & adding the most recent number of portions sold to the bottom of the list.
Continue process for all data.
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12. Moving Average Forecasting Model
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13. Exponential Smoothing Forecasting Model
All past data are considered in smoothing process.
More recent data are given more weight.
Requires only a few pieces of data to update a forecast.
Easily programmed & is inexpensive to use.
Rate at which the model responds to change can be adjusted mathematically.
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14. Casual Model
Assumption that an identifiable relationship exists between the item being forecast & other factors.
High costs for development & use.
Popular for medium- & long-term forecasts.
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15. Regression Analysis Forecasting Models
Most commonly adapted.
Includes:
Dependent variables – items being forecast.
Independent variables – factors determining the value of the dependent variables.
Requires a history of data to permit plotting over time.
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16. Subjective Model
Used when relevant data is scarce or patterns & relationships between data do not tend to persist over time.
Delphi technique
Market research
Panel consensus
Visionary forecast
Historical analogy
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17. Production Scheduling
Time sequencing of events required to produce a meal.
Planning stage:
Forecasts are converted into the quantity of each menu item to be prepared.
Distribution of food production to supervisors in each work center.
Action stage:
Supervisors prepare a production schedule.
Items are assigned to specific employees.
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18. Production Schedule Should include: Employee assignments
Preparation time schedule
Menu item
Over- & underproduction
Quantity to prepare: forecast amount for each menu item.
Substitutions
Actual yield: portion count produced by the recipe.
Additional assignments
Special instructions & comments
Pre-preparation
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19. Production Meetings
Should be held daily with employees in the production unit.
Employees encouraged to discuss the effectiveness of the schedule.
Free discussion of work loads.
Conclude with discussion of the production schedule for the following three meals.
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20. Ingredient Control
Begins with purchasing, receiving, & storage of foods.
Continues through forecasting & production.
Ingredient assembly – area designed for measuring ingredients.
Standardized recipes – provides assurance that standards of quality will be consistently maintained.
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21. Advantages of Centralized Ingredient Assembly
Contributes to the cost reduction & quality improvement.
Redirection of cooks’ skills away from collecting, assembling, & measuring ingredients to production, garnishing, & portion control.
More efficient use of labor.
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22. Centralized Ingredient Control
Control of unused portions is facilitated because storage is located centrally rather than in various work units.
Ability to combine tasks for two or more recipes using similar ingredients.
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23. Function of the Ingredient Room
Primary function is to coordinate assembly, pre-preparation, measuring, & weighing of the ingredients.
Availability of appropriate equipment will help determine the activities to be performed.
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24. Ingredient Room Organization
Should be located between the storage & production areas.
Necessary equipment includes:
Refrigeration
Water supply
Trucks or carts for assembly & delivery
Worktable or counter
Scales
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25. Ingredient Room Staffing
Employees must be:
Literate
Able to do simple arithmetic
Familiar with storage facilities
Responsible for receiving, storage, & ingredient assembly.
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26. Ingredient Room Staffing
Ingredient assembly personnel considerations:
Size of operation
Frequency & time of deliveries
Size of ingredient room & location of other storage areas
Type, number, & complexity of menu items
Number of workstation to be supplied
Schedule for delivery of ingredients to production & serving areas
Extent of pre-preparation performed in ingredient assembly area
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27. Future of Ingredient Rooms
Centralized or food factories are being used for procurement & production.
Prepared menu items are distributed to several remote areas for final preparation.
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28. Recipe
Formula by which weighed & measured ingredients are combined in a specific procedure to meet predetermined standards.
Written communication tool that passes information from the foodservice manager to the ingredient room & production employees.
Quality & quantity control tool.
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29. Recipes Recipes include: Name of food item Total yield
Portion size & number of portions
Cooking time & temperature
List of ingredients in order of use
Amount of each ingredient by weight, measure or count
Procedures
Panning or portioning information
Food safety (HACCP) guidelines.
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30. Format All recipes in an operation should be in the same format.
Common large quantity formats:
Block format
Complete block format
Modified block format
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31. Block Format Ingredients listed on left side of recipes.
Procedures directly opposite ingredients on right side.
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32. Complete Block Format
Horizontal lines separate each group of ingredients with procedures.
Vertical lines separate the ingredient, amount, & procedure columns.
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33. Modified Block Format Most common
Horizontal lines separate the required ingredients for each procedure.
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34. Format Additional information often added at bottom or on back:
Approximate nutritive values per portion
Variations on the recipe
Special serving instructions
Storage requirements before & after service
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35. Format
Recipes should be in large print easily readable from inches.
Recipe name should be in bold letters.
Major categories (breads, meat, salad, etc.) may be color coded to make identification easier.
KEEP BACKUP OF RECIPES!!!
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36. Standardization
Ideal to have recipes that consistently deliver the same quantity & quality product when followed precisely.
Recipe standardization – process of tailoring a recipe to suit a particular purpose in a specific foodservice operation.
Requires repeated testing.
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37. Justification Advantages for using standardized recipes:
Promote uniform quality of menu items.
Promote uniform quantity of menu items.
Encourage uniformity of menu items.
Increase productivity of cooks.
Increase managerial productivity.
Save money by controlling overproduction.
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38. Justification Advantages (cont.):
Save money by controlling inventory levels.
Simplify menu item costing.
Simplify training of cooks.
Introduce a feeling of job satisfaction.
Reduce anxiety of customers with special dietary needs.
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39. Three Phases of Recipe Standardization
Standardized recipes:
Developed for use by a foodservice operation.
Found to produce consistent results & yield each time prepared.
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40. Three Phases of Recipe Standardization
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41. Recipe Verification Review components of the recipe Recipe title
Recipe category
Ingredients
Weight/measure for each ingredient
Preparation instructions
Cooking temperature & time
Portion size
Recipe yield
Equipment to be used
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42. Recipe Verification Make the recipe Verify the recipe yield
Record changes to the recipe
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43. Product Evaluation Informal Evaluation: Visual appearance Flavor
Ability to obtain ingredients
Cost per serving
Labor time
Availability of equipment
Employee skill
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44. Product Evaluation Formal Evaluation
Select group of staff members & customers as a taste panel.
Choose or develop an evaluation instrument.
Prepare sample recipe.
Set up sampling area.
Sampling & evaluation of products.
Summarize results.
Determine future plans for the recipe.
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45. Quantity Adjustment Methods include: Computer software also available
Factor method
Percentage method
Direct reading measurement tables
Computer software also available
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46. Factor Method Change ingredient amounts to whole numbers & decimals.
Divide desired yield by the recipe yield to determine the conversion factor.
Multiply all recipe ingredients by the conversion factor.
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47. Factor Method
Reconvert decimal unit back into pounds & ounces or quarts & cups.
Round off amounts to quantities simple to weigh or measure.
Check math for possible errors.
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48. Percentage Method
Convert all ingredients from measure or pounds & ounces to tenths of a pound.
Total the weight of ingredients in a recipe after each ingredient has been converted to weight in the edible portion.
Calculate the percentage of each ingredient in the recipe in relation the total weight.
Check the ratio of ingredients.
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49. Percentage Method
Establish the weight needed to provide the desired number of servings.
Add handling loss to the weight needed.
Multiply each ingredient percentage number by the total weight to give the exact amount of each ingredient needed.
Convert to pounds & ounces or to measures.
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50. Direct Reading Measurement Tables
Quick to use & require no mathematical calculations.
Used to adjust weight & volume of ingredients in recipes that are divisible by 25.
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51. Adapting Home-Size Recipes
Special considerations are necessary:
Know exactly what ingredients are used & in what quantity.
Make the recipe in original home-size quantity.
Evaluate the product for acceptability.
Proceed in incremental stages in expanding the recipe.
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52. Adapting Home-Size Recipes
Special considerations are necessary:
Determine handling or cooking losses (5%-8% loss is typical).
Check ingredient proportion against a standard large quantity recipe.
Evaluate products using taste panels.
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53. Quantity Food Production
Involves:
Control of ingredients
Production methods
Quality of food
Labor productivity
Energy consumption.
Sweet Spot – point of best value at lowest cost.
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54. Objectives of Food Production
Primary reasons to cook food:
Destruction of harmful microorganisms
Increased digestibility
Change & enhancement of flavor, form, color, texture, & aroma
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55. Heat Transfer
Conduction – the transfer of heat through direct contact from one object to another.
Convection – distribution of heat by the movement of liquid or vapor.
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56. Heat Transfer
Radiation – generation of heat energy by wave action within an object.
Induction – use of electrical fields to excite the molecules of metal cooking surfaces.
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57. Moist Heat Use of water or steam for the cooking process.
Simmering or stewing – cooking in a liquid that is boiling gently (185º-205º F).
Poaching – cooking in a small amount of liquid that is hot but not bubbling (160º-180º F).
Blanching – cooking an item partially & briefly.
Braising – cooking food in a small amount of liquid, usually after browning it.
Steaming – cooking food by exposing them to direct steam.
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58. Dry Heat
Use of dry air, hot metal, radiation, or a minimum amount of hot fat for the cooking process.
Includes:
Broilers – heat source 3”-6” from food.
Deep Fat Fryers – food immersed in tank of oil heated by gas or electricity.
Ovens – combination of conduction, convection, & radiation.
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59. Multifunction Equipment
Combination of several pieces of equipment to increase space in production area.
Combi-oven – includes convection and/or steam
Tilting skillet – combines range, griddle, kettle, stock pot, & frying pan.
Convection/microwave oven - includes convection and/or microwave
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60. Production Controls
Quality control – assuring day-in, day-out consistency in each product.
Quantity control – producing exact amount needed.
Controls:
Time & Temperature Control
Product Yield
Portion Control
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61. Energy Use
Direct energy – energy expended to produce & serve menu items.
Indirect energy – energy expended to facilitate functions that use direct energy.
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62. Energy Conservation
ENERGY STAR®: partnership which promotes energy efficiency in buildings & homes.
Energy conservation checklist:
Food Preparation
Refrigeration
Lighting
HVAC
Sanitation & water
Office & Administration
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63. Energy Management Should include:
Record-keeping system for tracking utility costs & monitoring equipment use.
Employee training
Use of energy efficient equipment
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