Production

PRODUCTION

Food Production

1)      Objectives of cooking in Food Production

ü  Enhance the aesthetic appeal of the raw materials such as color, texture and flavor.

ü  Destroy harmful organisms to ensure that the food is totally safe for human consumption

ü  Improve digestibility and maximize nutrient retention

2)      Computers in Production

ü  The computer makes it easier  to adjust recipes once the recipe base has ben entered.

ü  Management of recipe files.

Recipe Formulation

1)      Standardized Recipes

                                 i.            Format

·         Provides all information needed for production of a menu item should be selected.

·         Each foodservice should decide on the format best suited to its operation and use this format consistently.

                               ii.            Recipe Title

·         Should be printed in large type and either centered on the page or placed to the left of the top of the page.

                              iii.            Yield and Portion Size

·         Yield may be provided in measure, weight, number of pans, or number of portions.

·         Portion size may be in weight, measure or count.

·         Important to define the serving utensil for portioning so service staff can portion accurately at the front of the house.

                             iv.            Cooking Time and Temperature

·         Often listed at the top of the page so preheating of equipment and scheduling of cooking can be determined without reading the entire recipe.

                               v.            Ingredients and quantities

·         Names of ingredients are usually listed on the left side of the recipe with the quantities arranged in one or more columns to accommodate different yields

                             vi.            Procedures

·         Should be clear and concise for make the employees can easily read and understand them.

·         The procedures on the recipe should be worded the same in each recipe.

                            vii.            Recipe Yield

·         Simply a measure of the total amount produced by a recipe.

·         Recipe yiled can be expressed in weight, measure or count.

                          viii.            Quality Standards

·         Measureable statement of the aesthetic characteristics of food items.

·         Serve as the basis for sensory analysis of the prepared product.

·         Include appearance, color, flavor, texture, consistency and temperature.

2)      Recipe Adjustment

                                I.            Factor Method

      The quantities of ingredients in the original recipe are multiplied by a conversion factor.

      Steps:

a)      Divide the desired yield by the known yiled of the source recipe to obtain the conversion factor.

b)      Convert all volume measurements to weight.

c)       Multiply the amount of each ingredient in the original recipe by the factor.

d)      Round off unnecessary or awkward fractions.

                              II.            Percentage Method

      The percentage of the total weight of the product is calculated for each ingredients.

      This method is based on the weights expressed in pounds and decimal parts of a pound.

      Steps:

a)      Convert all ingredients in the original recipe from measure or pounds and ounces to pounds and thenths of a pound.

b)      Total the weight of ingredients in the recipe.

c)       Calculate the percentage of each ingredient in relation to the total weight.

d)      Check the ratio of ingredients, which should be in proper balance before going further.

e)      Determine the total weight of the product needed by multiplying the portion weight expressed in decimal parts of a pound by the number of servings to be prepared.

f)       Add estimated handling loss to the weight needed.

g)      Multiply each percentage number by the total weight to give the exact amount of each ingredient needed.

                            III.            Adapting small-quantity recipes

      Be sure that the recipe is appropriate to the foodservice and that the same quality can be achieved when prepared in large quantity.

      Steps:

a)      Prepare the product in the amount of the original recipe

b)      Evaluate the product using a written form and decide if it has potential for the foodservice

c)       Double the recipe or expand to the appropriate amount for the pan size that will be used and prepare the product

d)      Double the recipe again

e)      If the product is satisfactory, continue to enlarge by increments f 25 portions or by pans.

Forecasting Demand 

1)      Reasons for Forecasting

Ø  Minimizes the chance of overproduction or underproduction.

Ø  Serve as a means of communication with purchasing and food production staff.

2)      Historical Data

Ø  Used to determine needs and to establish trends in all forecasting method.

Ø  The data must be consistently and accurately recorded.

Ø  Depending on the type of foodservice organization:

a.       Restaurant/cafeterias

§  Customers served per meal

§  Menu items sold per meal period

§  Beverage sales

b.      Schools

§  Student enrollment

§  Students purchasing full USDA meal

§  A la carte items sold per lunch period

§  Teachers and staff purchasing meals

c.       Hospitals

§  Daily patient census

§  Patients on therapeutic diets

§  Daily patient admissions and discharges

d.      Vending Services

§  Product placed in machine at each fill

§  Total cash removed

§  Food remaining in machine at each refill

`              

3)      Criteria for Selecting Forecasting Methods

Factor	Considerations
Costs	ü  Development, implementation and system operational costs are reasonable ü  Training and education for staff
Accuracy/relevancy	ü  Past data and food selection patterns are relevant and accurately reflect current demand
Lead time	ü  System allows adequate time for purchasing, delivery and production ü  Accounts for perishability of food items
Pattern of behavior	ü  System can be adjusted for changes in menu item demand as a result of seasonality and consumer preference
Ease of use	ü  Use of system is easily understood ü  What knowledge and skills are required to operate system?
Level of detail	ü  System can generate desired forecasts ü  What is to be forecasted?
Responsiveness	ü  System generates accurate information on a timely basis

4)      Forecast Models

i.                     Moving average

v  Referred as a time series method of forecasting and is easy to use.

ii.                   Exponential smoothing

v  Another time series, similar like moving average but that it accounts for seasonality of data and adjusts for forecast error.

iii.                  Regression and autoregressive moving average

v  Sophisticated statistical methods in which past data are analyzed to determine the best mathematical approach to forecasting.

5)      Trends in Predicting Production Demand

      Trend in food preferences and service styles have greatly influenced the use of formal forecasting methods.

      Service styles in other types of on-site foodservice have also reduced the value of long-term forecasts.

Quantities to Produce

      The forecast is the basis for estimating in advance the quantities of menu items to be prepared and foods to be purchased or requisitioned from the storerooms.

      Steps:

i.                     Determine the portion size in ounces

ii.                   Multiply portion size by the estimated number to be served and convert to pounds.

iii.                  To determine the amount to order

iv.                 For foods to be puchased, convert the amount needed to the most appropriate purchase unit.

Production Scheduling

·         It is a decision making and communication process whereby the production staff is informed of how the actual activity of food preparation is to take place over a specified unit of time.

·         The purpose: to ensure efficient use of time, equipment and space by identifying:

a)      What menu items to prepare

b)      What quantities to produce

c)       When individual items are to be produced

d)      Who is to prepare each item

·         The sequence of food flow may include:

      Preparation of ingredients, including thaw time for frozen meats, cleaning and peeling vegetables

      Production of menu items, including combining ingredients and cooking

      Holding under appropriate conditions (frozen, refrigerated, hot-hold)

      Transport and service to customers

1)      Production schedules

Ø  A detailed document used to communicate with the production staff the work that needs to be done for a specific period of time.

Ø  Well-designed production sheets will include:

§  Work to be done

§  Who is to perform the specific tasks

§  Amounts of individual menu items to produce

§  Source recipe, identified by name and code number

§  Standard portion sizes and variations for specific service units and for modified diets

§  Target completion times.

2)      Production Meetings

Ø  A meeting with the production staff to discuss the menu and production plans heightens the effectiveness of the written production schedule.

Ø  No amount of paperwork can replace the human element in food production.

Production Control

1)      Ingredients Assembly

      Personnel and equipment

-          It is crucial that the ingredient room personnel be well qualified and that they be provided with adequate equipment.

-          Personnel assigned to the ingredient room mudt be able to read, write and perform simple arithmetic.

-          Weighing is the quickest, easiest and most accurate means of measure, so good scales are essential.

-          A list of equipment included in a centralized ingredients area:

v  Worktable

v  Counter scales

v  Mobile storage bins for sugar, flour, and other large-volume staples

v  Shelving for bulk staples and spice

v  Refrigeration

v  Sink and water supply

v  Can opener

v  Trash receptacles

v  Counter pans with lids if canned food are opened

v  Trays for assembling ingredients

v  Rubber spatula

v  Measuring utensils

v  Scoop for dipping flour and sugar

v  Packaging materials

v  Masking tape and marking pens to label ingredients

2)      Portion Control

Ø  Used to contain costs and ensure nutrient composition of menu items

Ø  Food is portioned by weight, measure or count.

Ø  Portion control can be intregrated into the purchasing function.

Ø  A knowledge of common can sizes is also important in portion control.