3 Food Preparation print

Food Preparation The overall sequence of receiving, storing, preparing, production, tray assembly, bay loader need to be achieved by: Minimum movement Minimum back-tracking Maximum use of space Maximum use of equipment Minimum expenditure of time and effort 1

Production kitchens After foods are cooked, they are rapidly chilled to below 5c and then stored below this temperature until required for packing. Processes are designed to comply with good practice for cook-chill operations. 2

The basic elements of the flight kitchen can be arranged on the basic of - Cold Wet areas - Hot Wet areas - Hot dry areas - Dirty areas 3

Cold Wet areas Vegetable and fruit preparation, poultry preparation, sea food preparation Hot Wet areas Boiling, poaching, steaming Cold Dry areas Cold meat slicing, terrine and pate cutting, garnish production, salad production Hot Dry areas Roasting, baking, grilling, sautéing, braising, Dirty areas frying. Small equipment cleaning, dish washing All production areas have strict hygiene requirements. Floors must be constructed with non-slip surface. The design must minimize possibility of accessible by insects and rodents. 4 SDU Hua Hin Campus/09Feb2015

Fruit and vegetable preparation This area requires sinks for washing vegetables together with stainless steel tables for manual operations and preparation machinery including peeling, shredding, cutting, and slicing. Prepared materials are packed into plastic boxes or wrap in plastic bags with sticker ‘Date of cleaning and packing’ ready for transfer to the hot or cold kitchen. 5

Meat preparation Same as vegetable preparation area with specialized equipment including mincing machine, choppers and dicing machine. Raw meats are brought in pre-portioned servings such as steaks and cutlets in order to reduce space required for meat preparation. The meats are cooked by any required method. 6

Once raw meats have been prepared, they are transferred to plastic storage boxes and held in refrigerated storage until required by hot kitchen. 7

Fish preparation Similar to the meat preparation area. Fish products will include raw fish (fresh, frozen), smoked fish and cooked fish products. It is essential to ensure that the preparations of raw and cooked items are completely separated. For good hygiene practice, separate color-coded, impervious, hard rubber chopping boards are required to avoid bacteria cross-contamination. 8

Hot Kitchen This area makes use of large-scale batch production equipments such as boiling pans and ovens, continuous frying equipment. Sophisticated ventilation systems are often installed. 9

Cold Kitchen This areas use for preparation of First course, cold meats, sandwiches and salads. The areas require slicing machine to control weights of cold meat per serving. Cooked meats are delivered (chilled to below 5c) or ready cooked. 10

Prepared items are held in refrigerated storage until required for tray assembly. Cold kitchen work has possibly moved to assembly. 11

Bakery/pastry This part of the preparation area covers the making of all desserts and baked goods. A decision regarding the buying-in of ready-made bakery produces or an in-house bakery would depend on each unit requirement. . 12

The basic requirement is for mixing machines, molding machines, proving ovens and baking ovens. With mass production, a computer- controlled machine can be used to weight all ingredients automatically into the mixer. Once dough is mixed, it is divided and shaped. 13

Pastry products such as cakes, pastries, quiches, puddings and fruit salads also require preparation space and equipment such as dough mixer, pastry rolling machine and refrigerated storage. Finished goods are loaded onto trolleys for transport to tray assembly area 14

Holding system and facilities Because foods are prepared on ground and consumed by passengers in the air, there has to be some way of ‘holding foods’ under safe conditions between their preparing in production rooms and their service in the aircraft. The most common of these used in flight catering is cook-chill. 15

Cook-chill Cook-chill is catering system based on the full cooking of food followed by fast chilling and store in controlled low temperature conditions just above freezing point (0c to 5c). 16

In order to preserve the appearance, texture, flavor, nutritional of quality and safety to the cooked food, blast chilling should commence as soon as possible after completion of cooking and in any event within 30 minutes of leaving the cooker. The blast chiller should have a performance to reduce the temperature from 70c to 5c in a period within 2 hours when fully loaded. 17

Cook-freeze Same as Cook-chill but controlled low temperature conditions below freezing point (-18c or below). The food should reach -5c to -18c within 2 hours of entering the freezer. It may be stored for up to 8 weeks. Coding the containers with product identification and expiry date should be used so that the stock can be rotated on FIFO. 18

Benefits Cook-chill Cook-freeze Limited nature, should Much tighter Preservation of food be destroyed ** * Storage life is short ** Ensure quality control *** Stock control capability *** Microbiological control *** and Hygiene 19

Food Production Time Control Before Departure 36 Hours 24 Hours 16 Hours Before departure Before departure Before departure Receiving Preparation Production 15 Hours 11 Hours 8 Hours Before departure Before departure Before departure Blast Chiller Chilling Dish packing 6 Hours 2 Hours 1 Hours Before departure Before departure After departure Tray assembly Uplift Serving 20

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