Industrial kitchen ?

•INDEX

1.What is a Industrial kitchen ?

2.Spatial Planning

3.Flooring

4.Walls and Ceilings

5.Ventilation

6.Lighting

7.Storage

8.Fixtures, Fittings and Equipment

9.Gas connection

10.Water Supply & Drainage, Electrical

11.Waste

12.Staff Amenities

13.Fire Safety

14.Conclusion

15.Bibliography

16.What is a Industrial kitchen ?

•2. Spatial Planning

ØSpatial Requirements

A well planned kitchen should:

•Provide adequate storage for raw materials.

•Provide adequate space for food being prepared.

•Provide adequate space food awaiting service.

•Provide adequate storage for equipment, utensils, crockery and cutlery.

•Be efficient and effective in terms of movement of staff, equipment, materials and waste management system in place Food & Oil

•Provide an area for checking in stock.

ØWork Flow

•The premises shall be designed so that there is a continuous progression of food from delivery to storage, through to preparation and the finished product, with no cross over to avoid cross contamination.

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ØFood Delivery or Receiving

•This includes the receiving of purchased goods, which involves: handling, checking, recording or storage. Some of these functions may be combined or not needed depending on the size of the kitchen.

ØStorage

The amount of storage space and the type of storage will depend on:

•The size of the kitchen.

•Menu.

•The volume of business.

•Delivery frequency.

•The length of storage.

•The type of storage (frozen, refrigerated or dry).

•Storage of meats, poultry and fish should be taken into consideration when designing the kitchen and kept separate from dry foods, vegetables, fruit and pastry.

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ØPreparation and Cooking

The main preparation areas in food premises are for:

• Meat preparation.

• Poultry preparation.

• Fish preparation.

• Vegetable preparation.

• Pastry/dessert preparation.

•All food preparation areas should be separate from the cooking area. Each preparation area should have one single sink per station separated by a physical or air gap to reduce cross contamination. Hand basins should be in these areas.

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ØClean Crockery

•Storage for clean crockery should be close to the washing up facility to minimize excess movement around the kitchen and ideally in a separate room due to the air pollution in a kitchen.

ØProvisions for Adequate Space

•Space shall be provided on the premises for staff to handle food and perform other activities that are part of the food business.

Space should be provided for:

•Staff changing room.

•Food preparation and service.

•Separation of raw food preparation from cooked food preparation and other ready-to-eat food preparation areas.

•Washing and sanitizing operations for utensils and equipment.

•Separation of food storage and handling areas from areas for chemical storage, toilets, waste storage, office areas and other areas used for activities that could contaminate food or food preparation areas

•3. Flooring

ØFloor Finishes and Serviceability

•Floors in food premises must be able to be cleaned effectively and thoroughly, must not absorb grease, food substances or water, harbor pests, and should be laid so as not to cause pooling of water.

Following is a list of suitable industrial kitchen flooring surfaces:

•Stainless steel with a non-slip profile and welded joints.

•Ceramic tiles with epoxy grouting.

•Quarry tiles with impervious sealer.

•Poly vinyl sheet or tiles with heat welded joints.

•Steel trowel case hardened concrete with epoxy sealant.

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•4. Ceilings and Walls

•The minimum height for a ceiling in a Industrial kitchen should not be less than 2400mm. This includes ducting, all preparation and storage areas. All ducting should be enclosed above the ceiling to prevent dust and insects collecting and falling in food.

•The finished ceiling surface must not have any perforation or exposed joints, cracks or crevices. This is to prevent the contamination of food and enable effective cleaning of the surface. This also ensures that the ceiling is pest proof.

•Suspended acoustic tile ceilings are not permitted in food preparation areas or where food is displayed or served.

•They are difficult to clean to the required hygiene standards and may harbor dust, grease and insects at the top of

•the drop ceiling.

•The wall-to-ceiling junction must be tightly joined and sealed. The junction must be constructed so that no dust, grease or food particles can collect in the joint.

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•Where a sealant is used in the ceiling joint it must be made of a material that is impervious and washable

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ØWalls

•The finishes on the walls must be impervious to grease, food particles and water.

•The finish must be smooth and even. The surface should have no buckles, ledges or exposed fixings. 

•The finished surface of the walls must be easy to clean.

Recommended finishes include:

•Ceramic tiles with anti-bacterial grout.

•Stainless steel or aluminum sheet with welded joints and sealed fixings.

•5. Ventilation

•This section refers to the management of air quality inside a Industrial kitchen, the amount of airflow, its supply and the exhaust of airborne cooking waste. An effective Industrial kitchen ventilation system requires ‘air balance’, in which the exhausting of fumes, smoke, grease and steam is balanced by the introduction of fresh, clean air. In busy kitchens where people are generally working close together there is a need for some form of controlled ventilation and air conditioning. The kitchen exhaust system is an essential part of the cooking process. The presence of fumes, smoke, grease, steam and vapors pollutes the atmosphere, may interfere with food flavors and aromas, and cause distress to staff.

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ØNatural Ventilation

•An adequate supply of clean air must be provided and maintained within a Industrial kitchen using gas. The simplest form of ventilation is natural, involving the use of windows, vents and skylights. These should allow sufficient airflow to maintain a healthy working environment. All vents should be screened to prevent flies and be rodent proof.

•If no replacement air by natural or mechanical means, the ventilation will suck the air from the restaurant drawing in the warm air / cool air from the restaurant increasing the running cost. Replacement air provides the airflow required by exhaust systems. If replacement air doesn’t come into the room, then the exhaust hood may not capture and contain airborne cooking waste due to the reduced airflow. This could allow cooking odors and waste air to escape into the dining area. If there is no replacement air in kitchen, when using gas appliances, lack of replacement air can cause the gas burners to go out because of lack of oxygen.

•Considerable care should be taken where doorways and windows are used for natural ventilation that fumes, dirt and rodents from surrounding premises are not drawn into the kitchen.

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ØExhaust Systems

•Exhaust systems are made of a number of interdependent units. Exhaust hoods, exhaust fans, make-up air units, and

•packaged rooftop HVAC (Heating Ventilation Air Conditioning) units all need to operate within defined parameters

•to complement one another and to maintain peak performance.

•The exhaust canopy must cover all cooking appliances with an overhang of 150mm to capture the cooking fumes.

•An effective exhaust system should get rid of:

•Heat.

• Particulate matter.

• Grease laden steam.

• Cooking vapours.

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•6. Lighting

•Diffuser: A cover over a light fitting which promotes an even distribution of light throughout the area.

•Glare: Light that is too bright or intense.

•Illuminance level: The amount of light falling on a surface.

•Luminance level: The amount of light that is reflected from a surface, such as walls, floors and ceiling.

•Splash back: An area of impervious material such as metal, tiles etc which is fixed to a wall behind a workbench or sink.

ØGeneral Requirements

•Adequate and properly designed lighting is essential in a Industrial kitchen for staff to efficiently do their tasks including cooking, cleaning, food preparation and presentation. The area should be as free from glare and unwanted reflections as is practicable.

•The design of a lighting system should take into account:

•Available natural light.

•Required luminance levels (lux) for the tasks being performed.

•Reflectance of surfaces.

•Emergency lighting requirements.

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ØNatural and Artificial Lighting

•The relationship between natural and artificial lighting is important to consider when lighting a Industrial kitchen. While artificial lighting will normally be the main source of light, it is desirable to include natural light sources. Ideally windows in the kitchen should not be less than 10 percent of the total floor area, and should look out onto the sky or open space.

•Windows and skylights can provide views and allow light into a space, improving the staff working environment, however they can also be problematic as a source of glare. Careful consideration should be given to the positioning of windows and the interaction between natural and artificial light levels.

•The recommended luminance level for a Industrial kitchen’s general working area is 160 lux. For food preparation, cooking and washing areas the luminance should be 240 lux. Dessert presentations and cake decorating require 400 - 800 lux.

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ØEmergency Lighting

•Emergency lighting ensures that patrons and staff are able to be safely and effectively evacuated from the premises.

•Emergency lighting turns on automatically from its own power supply whenever there is a power failure.

•The emergency lights must be positioned at exits, at any point where there is a potential hazard (e.g. a change in floor level) and at regular intervals to maintain minimum lighting levels.

•The location of emergency lights should not cause excessive glare and interfere with a person trying to leave the premises.

•Emergency lighting systems must be maintained on a regular basis and maintenance checks recorded in a log book.

•7. Storage

ØStorage Requirements

•The need for separate storage rooms will depend on the scale of the kitchen, however, consideration should be given to specific storage needs for the following:

•Dry goods.

•Chilled and frozen foods.

•Fresh fruit and vegetables.

•Returned/recalled foods.

•Packaging material.

•Cooking utensils and equipment.

•Cleaning equipment.

•Clothing and personal belongings of staff.

•Garbage and recyclable materials.

•Storage facilities must allow the safe retrieval of stored items.

•Waste oil storage (bunding).

•Staff lockers.

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•8. Fixtures, Fittings and Equipment

General Requirements

•Fixtures, fittings and equipment within a food premises must be adequate for the safe production of food. All surfaces must be non Porous, i.e. stainless steel (Wood is not to be used in the kitchen area). 

The operations of a kitchen require adequate fixtures, fittings and equipment for the following operations:

•Serving food.

•Packaging.

•Transporting.

•Storing recalled food or food for disposal.

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Depending on the activities undertaken, the following equipment may be required:

• Cool rooms and refrigerators for chilled storage.

• Benches and work tables for preparation.

•Ovens, stoves and other such equipment for cooking.

•Hot boxes and ovens capable of holding food at 63ºC or above (hot hold).

• Display units that protect food from contamination and hold the food at 63ºC or above (hot display). 

• Display units that protect food from contamination and hold the food at 5ºC or below (chilled display).

•Blast chillers that can reduce the temperature as specified in local regulations.

•Portable RCDs (if electricity supply for movable equipment is not RCD protected).

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9. Gas connection.

10. Water Supply & Drainage and Electricity

ØWater supply

Water supply is required for the following:

• Drinking.

• Cooking.

• Ice making.

• Cleaning.

•Sanitizing.

• Personal hygiene.

• Fire suppression systems (fire hydrants, hose reels and sprinkler systems).

•Separate non-potable water supplies are often used for fire suppression systems e.g. recycled rainwater. Hot water must be stored at a minimum of 60ºC to prevent growth of bacteria such as Legionella. Water pressure must be adequate to meet all the demands of the Industrial kitchen.

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ØDrainage

•Waste removal at source is a simple concept in a highly complex world.

•If waste which can be dealt with through composting or land fill is not introduced into our sewage systems the loading on the system is reduced. When best kitchen practices are applied and adhered to, e.g. use of paper wipes to clean surfaces and spray applications will eradicate the introduction of disinfectant and sanitisers into the drainage system. Capturing FOG before it enters the drainage system is the best solution which Aluline has been encouraging sites to do for the past twenty years. Bio film which is created by oil, suffocates the aerobic bacteria and therefore can lead to blockages, as the bacteria is the cleaning agent for our waste water network. Bacteria are the key to a proper functioning drainage system. We are not referring to “commercial bacteria” dosed to enhance drainage systems but the natural bacteria contained in all living organisms.

•The aerobic bacteria in pipes and tanks require oxygen to carry out its function of digesting organic materials flowing through pipe lines.

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ØElectricity

•Warewashing: Dish and glass washers.

•Freezers and Fridges: All walk-in, stand alone and under counter refrigeration and freezing units, ice machines and cellar beverage chillers.

•Cooking : All appliances utilized to prepare meals and store hot food, coffee machine.

•Lighting: All external and internal lighting. Air Handling All

•Air Handling: including ventilation, central heating, air conditioning and cellar cooling.

•Other Sundry sockets used ad-hoc (vacuum etc.), building alarms, hand driers. beverage pump, and office computer.

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ØMaterials

•Surfaces in contact with food must be easily cleaned, and not be able to absorb grease, food particles or water. Stainless steel: suitable in direct contact with food. It is durable and can withstand chemicals. It is available in various grades which should be chosen based on the application.

•Stainless Steel

•Should only be used in a kitchen with 304 grade steel. This has a low content of iron and will not rust.

•Iron and mild steel

•Should not be used in the kitchen.

•Timber products

•Timber should not be used in a kitchen. Only in specific circumstances such as butchery and some bread-making

•operations should timber be used.

•Plastics

•Plastic laminate and solid surface materials are suitable surfaces for food preparation. All surface should be non porous

•to ensure ease of cleaning. Note; when surface becomes scored or scratched it should be replaced.

•11. Waste

ØDisposal Systems

•Disposal systems are the actions performed to remove waste in a Industrial kitchen from the premises. The kitchen’s waste disposal system should be developed to prevent the occurrence of injury resulting from manual handling tasks (e.g. lifting of waste containers).

Appropriate measures need to be taken to dispose of the following:

•Food for disposal

•Garbage

•Recyclables

Food for disposal is food that is:

•Previously served.

•Unsafe or suspected of being unsafe.

•Unsuitable or suspected of being unsuitable.

•To be recalled or returned.

•Out of date

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•12. Staff Amenities

ØPersonal Hygiene

Personal hygiene of staff is important to prevent contamination of food.

Posters or signs should be displayed in kitchens to make staff aware of:

•The correct procedures for washing hands, and when this must be done

•What do in the event of a minor illness (for example, a cold)

•The business’s policies regarding grooming, clothes, wearing of jewellery, tying of hair etc.

ØStorage of Personal Items

•Staff should be provided with adequate and secure storage for clothing and personal belongings. If not located in dedicated staff change rooms, lockers should be located away from food preparation and storage areas to prevent possible contamination of food.

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ØChange Rooms

•Staff should be provided with dedicated change rooms, particularly when they are required to wear uniforms. Gender specific change rooms are not necessary for small businesses; however they should be provided for larger food businesses, and may be incorporated into toilet areas. Change rooms should not open directly onto kitchen areas.

ØToilets

It is essential that staff have access to toilets.

•For a small business located in a shopping centre, use of the centre’s public toilets may be adequate. For larger businesses, staff may share the toilet facilities provided for patrons; however, it is recommended that dedicated staff toilets be provided. Where no more than 10 staff are employed, a unisex toilet may be provided. A unisex toilet must include one pan, one basin and means of disposing sanitary products.

•Where more than 10 staff are employed, separate male and female toilets should be provided. The number of sanitary fixtures (toilet pans, urinals and basins) that must be provided depends on the number of staff and is set out in the Building Act 1984.

•13. Fire Safety

Basic fire precautions are:

• All areas should be kept clean from dust, dirt and oil to limit fire damage.

•All cooking and high-risk appliances should be watched when in use.

•Emergency Procedures

•All kitchens must have a written emergency evacuation plan in place. This plan should detail the following actions:

•When the alarm is activated the restaurant’s fire warden should receive the first warning.(or if part of a larger building their fire warden)

•Until the nature of the alarm, whether false or real, is known, employees and customers should continue as per usual.

•Once the fire warden has assessed the problem, he or she must call the appropriate services and decide upon evacuation.

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• Staff and customers are then to be evacuated in an orderly fashion as planned and practiced on previous occasions.

•Once evacuated, staff are to assemble in a predefined place and await further instructions.

•The fire warden is to stay and wait for emergency services and assist them if possible.

•A debriefing should occur after each evacuation (training or real) to identify problems with the process as well as to point out the positive aspects.

•All areas of restaurants MUST have at least one trial every 12 month period.

ØEmergency Manuals

•All manuals for emergency devices, solutions to dangerous situations and other emergency instructions etc. should be kept in the same place. They must be clearly labeled, well organized and easy to understand. If instructions are attached to the device, it is advisable to keep a separate copy with the other manuals.

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ØEmergency Devices

•Emergency devices should be dispersed around the kitchen, not all in the same area.

•Emergency equipment should be serviced at least once a year.

ØSprinkler systems

•Sprinkler systems as with fire hoses are not generally used unless the kitchen is large, mainly due to their high expense. If a sprinkler system is used, a misting type is generally recommended. They are however, very important for the eating area. Restaurants and cafés must comply with all fire safety standards for this occupancy type. If a sprinkler system is required in the restaurant.

•Fire detection systems

•These are more of a precaution than a solution. Smoke detectors do not work very well in kitchens. Steam and other vapours disrupt the efficiency of smoke detectors. Also small, easily contained fires are a common occurrence in Industrial kitchens that may unnecessarily trigger a smoke alarm. It is recommended to use heat detectors instead. Smoke/heat detectors are not to be placed more than 20 m apart and not more than 10 m from any wall. Gas shut off valve. This shuts off the gas to appliances in the kitchen. This should be situated at the exits of the kitchen easily seen and accessible.

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