EQUIPMENT REQUIREMENT FOR COMMERCIAL KITCHENS

There are various heavy and light equipments required for the commercial kitchens. Determining the specific equipment required for the proposed kitchen is one aspect of design on which considerable time can be spent. During this part of the planning process the food service facility consultant has to estimate accurately the capacity of each of the various types of kitchen equipment to be used. If these capacity estimates are too low, the result will be delays and bottleneck in the food production process. Estimates that are too high will result in expensive and inefficient piece of equipment. The consultant should be careful to take into account any projected increase in business volume, that would require increased equipment capacity, and plan accordingly. At this juncture, he has to make decision about the manufacturer, the model number, attachments, special accessories.

A systematic method of determining equipment capacity required is to analyse each food item appearing on the menu. Whether a la carte (or) daily change menu as in the case of buffets a sample of the typical menus may be sufficient. First, we have to estimate the number of portions to be prepared for a particular period. This estimate is made for every menu item requiring equipment. Next the standard portion size of the each food item has to be fixed. For e.g. (soup-240 ml., coffee-180 ml., etc.) multiplying the estimated number of portions by the portion size will give the total volume if food to be prepared.

Once the volume of food to be prepared is arrived, the capacity of the equipment should be determined with future changes anticipated. Trends can be studied, and then any anticipated changes in foods, sales volumes or meals offered can be projected to see if drastic changes in equipment are necessary. For e.g.: perhaps no freezer space will be required currently, but if the need for freezer space is highly probable is 5 or 10 years, space can be left to add it then conveniently and economically.

The method of preparations and production for each item is then evaluated. Possible alternatives may include a) items individually prepared to order. b) Items prepared in small batches in anticipation of orders, c) item prepared in large batches, d) item that are partially batch prepared and finished when orders are received.

The batch size is next determined for those items that are to be prepared batches. The selection of the batch size is one way that the food service facility consultant can control the capacity of the equipment. Smaller and more frequently prepared batches are desirable because they require less equipment capacity and the foods are fresher when served. Some items that can be held swell after cooking can be made in larger batches.

For those items to be prepared and cooked to order, the maximum no. Of portion to be made at one time is evaluated on the basis of the no. of customers, their menu preference, their arrival pattern.

After determining portions, equipments catalogs may be consulted to match the capacity needed for production with the available sizes of standard equipment. The designer is also careful when sizing some equipment that may have a usable capacity that is somewhat less than the standard capacity.

Equipment Check list

The equipment required for the kitchen varies from one type of operation to another depending on the menu offerings, the nature of food materials, method of preparation, service, personal desire of the owners, manager, or chefs. The following list of equipment is grouped by typical functional areas.

Refrigerated, storage

Cold Rooms:

• Shelves
• Dairy
• S.S.Trolleys
• Vegetables

FreezeRoom:

• Fish 
• Meat

Cold Kitchen

• Meat Saw 
• Gravity feed slicer 
• Meat Block 
• Reach in Refrigerator 
• Reach in Freezer 
• Scales 
• Work Table with service and drain board 
• SS Utility Trolley 
• Mincer – Chopper 
• Sausage Stuffer 
• Buffalo Chopper

Vegetable and Salad Preparation

• French-fry cutter 
• Peeler 
• SS preparation table
• Salad rack
• Vegetable cutter
• Slicer/Chopper 

Pantry

• Griddle
• Microwave oven
• SS worktable – sink drain board
• Toaster
• Salamander
• Reach in Refrigerator
• Bread Cabinet
• Juice extractor
• Coffee/Tea Pantry man
• Ice Cream cabinet

Cooking – All kitchens

Bain Marie counter with overhead heaters.
Chinese range
Condiment cabinet
S.S.work table
S.S. work table with sink unit
S.S.work table with OH shelf
Deck oven
Food warmer
Brat pan
Griddle
Grill
Gas cooking ranges (a la carte, Indian kitchen, Banquet, Halwaii)
Refrigerated Table
Reach in Freezer
Reach in Refrigerator
Salamander
Steam jacket kettle
Pot rack
SS utility trolley
Vertical cutter/Mixer
Dosa Plate
Chapatti Puffer
Wet Grinder

Bakery and Confectionery

S.S.Work Table

Bread Moulder
Bread Slicer
Cooling rack
Convection oven
Deck own
Dough divider
Dough rounder
Dough sheeter
Dough kneader
Weighing scale
Planetary Mixer
Proofing cabinet
Proofing rack
Ice cream machine

Snacks bar

S.S.Counter

Coffee maker
Food warmer
Freezer
Fudge warmer
Griddle
Grill
Gas range
Work table
Working table with sink and drain board
Slush Machine
Juice dispenser
Pastry cabinet
S/W grill
Soda fountain
SS utility trolley
Bain Marie counter
Chaat Counter
Dosa Plate

Pot work

Pot rack

Shelves
Sink
Pre rinse faucet
Water agitator
Drying rack

Wet Grinding

Convention wet grinder
Tilting model wet grinder
Worktable.

       A complete discussion of selecting and sizing of all the different types of kitchen equipments is beyond the scope of this study material. A brief discussion of frequently specified major items of equipments would serve to illustrate this part of the planning process.

A: DEEP FAT FRYERS:

Deep fat fryers are available in a variety of types, capacities and degree of automatic operation desired. The productive capacity of a fryer is related to the litres of fat in the fryers, the heat input, and the cooking time required for various foods. Typical designs of fryers are based on a fat-to-food ratio 6:1. This indicates that each kg. of food to be fried requires 6 lits. of oil (or) fat in the deep fat fryer. Conventional fryers are tailor made to the requirement of the client to various capacity, 1/2 lit, 1 lit. 3, 5, 7 and so on.

Pressure fryers make another category of deep fryers they are sealed to permit steam pressure to build up between the lid and the fat surface. The steam is generated from the foods fried or by water injectors. The pressure fryer reduces the loss of moisture from foods. Heat transfer in a pressure fryer is greater than a conventional fryer and consequently the cooking time is shorter. The food is brown outside, moist and juicy on the inside.

B. BRATT PAN (Tilting frying pan):

The brat pan is one of the most versatile pieces of cooking equipment. Its design is such that it can be used to boil, simmer, grill, sauté, fry and curries. For some items like Indian gravies, sambar, foogath can be done in the tilting frying pan with some savings in time that would normally be spent transferring foods and cleaning other utensils. Brat pan may be free standing; walls mounted, counter mounted and are available in gas and electricity model. There are models which are ignited by electricity and working on gas. The brat pan is tilted by a worm and gear assembly operated by hand wheel. They are tailor made to difference capacities of 50 litrs. to 300 litrs.

C. GRIDDLE:

Griddle are flat top piece of equipment heated from beneath, as compared to grills which have heating sources both above and beneath. Griddles are used for high production food service and fast food operations. Grills are more of a specialty piece of equipment. Both gas fired and electric models are suitable for most purposes. Griddle are available in variety of sizes from small i.e. 10” x 20” to as large as 72” x 24”. Griddles are free standing, counter-mounted, mobile or built in as the situation demands. The height of the splashguard, location and the width of the grease trough should be considered when specifying griddles. Combination griddle-grill is also available. This provides greater flexibility for the preparation of different menu items.

D.FOOD CUTTERS:

Food cutters are versatile piece of equipment that can handle meats, vegetable and fruits. The food cutters can cut, dice, shred, and almost liquefy foods, depending upon the amount of time the food is left in the cutter. The foods to be size reduced are placed in a bowl, which rotates and exposes them to high speed rotating blades. Both bench and floor models are available. Some cutter models are equipped with an attachment hub for accepting various attachments.

E. STEAM JACKETED KETTLES:

Steam jacketed kettles are constructed of two stainless steel bowls sealed one within the other, with almost 2” of space between them for the introduction of steam. The amount of steam surface between the bowls is referred to as jacketing, and models from half-jacketed to full jacketed are available. The operation of steam-jacketed kettles utilizes steam, which is condensed back to water in the jacket to provide the heat for the inner kettle. A condensate line is provided to remove the water that accumulates. The amount of heat input is dependant upon the pressure and amount of steam allowed to enter the jacketed area. There is a pressure gauge to indicate the pressure. In case of excess pressure is let into the jacket, there is a pressure /air release valve to reduce the pressure. These kettles are used to cook rice, dhal, boil milk, and cook vegetables. They are available in 50, 100, 200 and 300 lit. cap.

F.GAS COOKING RANGE:

Gas cooking ranges have open top burners with high-pressure burners, T-22, T-35. They are tailor made for the client’s is requirement. They are manufactured in different combinations such as 2 in 1, 3 in 1, 4 in 1 and 6 in 1. The length and breath of the range depends on the quantity food to be prepared. In case of a la carte preparation, a combination of high and low pressure burners is used, the area being 14”x 14”. The height of the cooking ranges 33” - 34”. But for ideal bulk cooking the length various between 20” to 24” per range, and. the height is reduced to 18” to 20”. Heavy gauge stainless steel and heavy-duty supports are used for these cooking ranges since it involves bulk preparation.

     A Chinese gas cooking range is aptly designed for authentic Chinese delicacies, with a cast iron dome, to prevent the direct heat on to the chef while cooking with a wok. A 12” to 14” height splash back with a swiveling faucet with controls in front panel for immediate water, and a drain channel at the rear to enable to chef to empty the wastewater is also provided in this equipment. They are ideal with flat open top gas range in the middle for stockpot and dome cover gas ranges on either side for a la carte preparations.

G. DOSA PLATE:

The dosa plate are similar to the griddle which have hot plates specially designed to prepare dosas. The plate is thick machine polished, mild steel with even heat distribution for optimum use.

The M.S.plate rests on stainless steel frame, and it has S.S.top, front and a specially placed oil spillage trough. The splash back on all three sides of the dosa plate to avoid splash of oil or batter. For uniform heat distribution a “V” shaped burner is placed. This unit is available in electric/gas. It is custom-built size to prepare a minimum 2-3 dosas to 8-10 dosas at a time.

H. IDLI STEAMER:

Idly steamers are S.S. cabinets with tight fitting doors with gaskets. Steam is injected into the cabinet to pre heat to the required temperature. Idly plates are made of S.S./Alum. with different combinations. The steam is injected from the sides, top and bottom. These cabinets are tailor made to accommodate 2-4-6 idly plates at a time. It is advisable to have 2 plate compartments because steam is lost during the process of loading the idly plates.

DEVELOPING SPECIFICATION FOR VARIOUS KITCHEN EQUIPMENTS.

STANDARD: After determining the type and capacity of the equipments required for a particular kitchen, the next phase involves selecting the specific characteristics that are desired. Factors such as

• Materials

• Constructions techniques
• Special features
• Maintenance consideration are evaluated.

STAINLESS STEEL: Stainless steel is an alloy containing minimum amount of chromium and nickel and maximum amount of other alloying elements such as manganese, silicon and carbon. Its use in kitchen equipments is based on the following characteristics: -

• High corrosion resistance

• High strength
• Hardness
• Durability
• Abrasion resistance
• Ease of maintenance

TYPES:  Kitchen equipments manufacturers and fabricators select from the stainless steel referred to have Type 304 and 302 (food grade). These stainless steel sheets produced in India, according to the standards of Steel Authority of India that controls the amount of alloying materials.

The corrosion resistance of stainless steel is attributed to the addition of Chromium to the alloy. Nickel lowers the thermal conductivity of the alloy and increases its co-efficient of expansion, allowing it to be formed into various shapes more easily. The amount of carbon is restricted so that the alloy can be welded without forming chromium carbide, which lowers corrosion resistance.

Stainless steel is produced in sheets, plates, bars, wires, pipes and tubing.

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ELEMENT                         TYPE  302 %                          TYPE 304 %
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CHROMIUM                      17-19                                         18-20
NICKEL                                8-10                                          8-12
MANGANESE                    2 max.                                       2 max.
SILICON                                 1                                                1
CARBON                            0.15                                               0.08
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FINISH:    A number of degrees of finishing are available for Stainless steel. There are 8 designated types of finish for stainless steel. They are achieved by standard guiding, polishing and buffing. The finish used for surfaces that are in direct contact with food or exposed is standard polish No.4. Non-food contact surfaces and non-exposed supporting frames and sheets can have a duller finish, which is less expensive than polished finish.

tHICKNESS:   The Swiss Wire Gauge (SWG) usually designates metal thicknesses. Although other gauges are manufacture, typical gauge numbers of metals used for kitchen equipments ranges from 6 to 24 (6 is the thickest and 24 is the thinnest). The actual dimensions for these typical gauges are given below:

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 GAUGE NUMBER                                 THICKNESS (inches)
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6                                                                   0.1943

7                                                                   0.1793
8                                                                   0.1644
9                                                                   0.1495
10                                                                 0.1345
11                                                                 0.1196
12                                                                 0.1046
13                                                                 0.0897
14                                                                 0.0747
15                                                                 0.0673
16                                                                 0.0598
17                                                                 0.0538
18                                                                 0.0478
19                                                                 0.0418
20                                                                 0.0359
21                                                                 0.0329
22                                                                 0.0299
23                                                                 0.0269
24                                                                 0.0239
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GALVANISED STEEL:

Coating the steel with a layer of Zinc produces galvanized steel. The preferred method of producing galvanized steel is by electroplating, which gives the best bond between the steel and zinc. The quality of galvanized steel is dependent upon the thickness of the zinc coating.

Galvanized steel can be satisfactorily used for kitchen equipments, where there is no food contact or where abrasion is not evident. Sinks, tables, counters, shelves, racks are manufactured with galvanized steel framework.

CONSTRUCTION STANDARDS:

Equipment manufacturers to produce the finished product utilize several fastening methods. The fastening of materials in the food zone has to be capable of meeting sanitary requirements while in non-food zones.

There are 3 fastening methods
• Welding
• Soldering
• Mechanical fasteners.

WELDING:   Welding is the preferred methods of joining sheets of metal that cannot be formed into the desired shapes. Heliarc welding is used on stainless steel if there is sufficient thickness of metal. The heliarc welding utilises an inert gas as the flux, resulting very smooth or strong weld. The weld can be ground and polished to the extent that the joint is equivalent to No.4 finish.