1. Week 10
Food and Beverage
Production Methods
By Aj. Pavit Tansakul
Tourism and Hospitality Management Program
School of Management, Walailak University
tpavit@wu.ac.th tel. 2248
http://tourism.wu.ac.th

2. Objectives
Describe the goal of production for foodservice operation
Describe the obstacles to the goals of production that are
inherent in a foodservice operation
State the possible solutions to these obstacles
Managing food production as an operating system
Knowing details of the main centralized production systems
available to the foodservice operator and advantages and
disadvantages of each

3. Outlines
1. Production from the customer s point of
view
2. The Goal of production
3. An obstacles to the goal of production
4. The possible solution for obstacles
5. Food Production System
6. Food Production Methods

4. 1
Production from
the customer’s
point of view

5. Production from the customer’s point of view
Customers of food service operation do not generally see
the production, or the preparation, of the food they eat
Most of the production goes on behind the closed doors of
the kitchen
They so se and eat the final products (Food and Beverage)
They are the final and most critical judges of the work of all
areas of the foodservice operation.

6. 2
The Goal of
Production

7. The Goal of Food Production
Should be the goal of the operation: to serve the customer
the highest-quality product possible in a reasonable
amount of time

8. The objectives of Production
1. Customer Appeal
2. Cost Control
3. Facilitate production and service
4. Material handling
5. Labor utilization
6. Supervision and management
7. Hygiene and safety standards
8. Cleaning and maintenance
9. Flexibility

9. 3
An Obstacles to the
goal of production

10. An Obstacles to the goal of production
Limited amount of time to eat for customer
A quick solution is to produce the food ahead of time. This
sounds contradicts the goal of providing the highest-quality
food possible.
Most food deterate in quality immediately after they are
prepared and as they are held for service.
Therefore, although preparing food ahead of time will
speed up service to the customer.

11. 4
The possible solution
for obstacles

12. The possible solution for obstacles
1. Steps of production Recipe should be separated
into various step of production
Example. Carrot can be
cleaned, peeled, and sliced,
partially cooked, then cooled

13. The possible solution for obstacles
2. Final Cooking Final cooking of an item
should be done as closely to
the time needed as possible.
Example, Baked potatoes,
must be cooked ahead while
being held hot, their quality is
reduced.
Solution may forecasting the
sale before making each day

14. The possible solution for obstacles
3. How to hold them Determine the best way to
hold items in various stages of
production.
Example. Frozen, peeled
potatoes under water

15. The possible solution for obstacles
4. Reuse menu items Kitchen staff should plan for
reuse of menu item that have
been made are not served.
Example, Baked potatoes can
be used for hash brown
potatoes

16. The possible solution for obstacles
5. Priority: Quality Remember to maintain quality
should be communicated to all
employees

17. 5
Food production
systems

18. Food production systems
Has to be organized to produce the right quantity of food at
the correct standard, for the required number of people on
time, using the resources of staff, equipment and material
effectively and efficiently.

19. Food production systems
The requirements of the production system have to be
clearly matched to the type of food that is to be prepared,
cooked an served, to the required market at the correct
price.
Many food production operations are based on the process
approach, as opposed to PARTIE system (product
approach)

20. Classic (French) Organization of Kitchen
Chef
(Executive Chef)
Sous Chef
(Assistant
Executive Chef)
Saucier Potager Poissoner Extremetier Rotisseur
(Sauce, Stock) (Soup) (Fish) (Vegetable) (Roasted Meat)
Grillardin Garde Patissier Baker Tournant
(Broiled Meat) Manger (Desserts) (Bread) (Swing Cook)
(Cold
Foods)

21. Food production systems
PARTIE system approach concentrates on the specific
techniques and processes of food production.
A whole range of different cuisines are able to fit more
neatly into this approach because the key elements focus
on the process, the way the food is prepared, processed,
stored and served.
Using this approaches, food production systems may be
identified using the input/process/output model

22. Elements of Food Production

23. 6
Food Production
Methods

24. Food Production Methods
1. Conventional Method
1.1 Traditional Parties Method
1.2 Conventional Production with Convenience Food
2. Centralized Production Methods
3. Cook-Chill Production
4. Cook-Freeze Production
5. Sous vide

25. 1.1 CV. Traditional Parties Method
RAW food supplies
Dry Goods Chill/Frozen store
Food Production Parties
Sauce / Roast / Fish / Larder / Soup / Vegetable / Pastry
Hold
Serve

26. 1.1 CV. Traditional Parties Method
The majority of food is purchased
raw, very ;little for convenience foods
Labor is intermittent, rising to peak
just before the service of each meal
This is an expensive way of running a
kitchen; because of the manpower
needed to operate it, its space,
equipment and energy requirements

27. 1.2 CV. With Convenience Food
Mostly are the same as
traditional method
production, but for this
method they introduced
a convenience foods
with rang from partial to
a virtually complete
reliance.

28. 2. Centralized Production Methods
Involve the separation of the
production and service
components.
Food that is centrally produced
is either then distributed to the
point of service in batches or is
pre-portion; it may be
transported in a ready-to-serve
state.

29. 3. Cook-Chill Production
Food production storage and regeneration method utilizing
principle of low temperature control to preserve qualities of
processed foods.
Low temperature conditions above freezing point, 0-3oc
Reheating immediately before consumption.
Require low capital investment and minimum staff

30. 3. Cook-Chill Production
Cook-chill, the process of food production, packaging, rapid
chilling and storage under controlled refrigeration, is most
commonly used in high-volume institutional settings. Its
advantages can benefit all types of operations, though,
especially banquet kitchens, recreational facilities,
commissaries and hotels.

31. 3. Cook-Chill Production

32. 4. Cook-Freeze Production
Production, storage and regeneration method utilizing
principle of freezing to control and preserve qualities of
processed foods.
Required special processes to assist freezing
E.g. sauces reheat when needed
Require high speed low temperature at least -20oc w/in 90
mins

33. Overall benefits of cook-chill and cook-freeze
For the operation
Good portion control and reduced waste.
No overproduction.
Central purchasing - bulk-buying discounts.
Full utilisation of equipment.
Full utilisation of staff time.
Overall saving in staff.
Saving on equipment, space and fuel.
Fewer staff with better conditions- no unsocial hours, no weekend work, no overtime.
Simplified delivery to units- less frequent.
Solve problem of moving hot food. (EC regulations forbid the movement of hot food unless
the temperature is maintained over 65°C (149°F). Maintaining 65°C is regarded as very
difficult to achieve and high temperatures inevitably will be harmful to foods.)

34. Overall benefits of cook-chill and cook-freeze
For the Customer
Increased variety and selection.
Improved quality, with standards maintained.
More nutritious foods.
Services can be maintained at all times, regardless of staff absences.
The advantages of cook-freeze over cook-chill are:
Seasonal purchasing provides considerable savings.
Delivery to units will be far less frequent.
Long-term planning of production and menus becomes possible.
Less dependent on price fluctuations.
More suitable for vending machines incorporating microwave.

35. Overall benefits of cook-chill and cook-freeze
For the Customer
Increased variety and selection.
Improved quality, with standards
maintained.
More nutritious foods.
Services can be maintained at all times,
regardless of staff absences.

36. The advantages of cook-freeze over cook-chill
are:
Seasonal purchasing provides
considerable savings.
Delivery to units will be far less
frequent.
Long-term planning of
production and menus
becomes possible.
Less dependent on price
fluctuations.
More suitable for vending
machines incorporating
microwave.

37. The advantages of cook- chill over cook-freeze are:
Regeneration systems are simpler: infrared and steam convection ovens are
mostly used and only approximately 12 minutes is required to reheat all
foods perfectly.
Thawing time is eliminated.
Smaller-capacity storage is required:3-4 days supply as opposed to up to
120 days.
Chiller storage is cheaper to install and run than freezer storage.
Blast chillers are cheaper to install and run than blast freezers.
Cooking techniques are unaltered (additives and revised recipes are needed
for freezing).
All foods can be chilled so the range of dishes is wider (some foods cannot
be frozen). Cooked eggs, steaks and sauces such as hollandaise can be
chilled (after some recipe modification where necessary).
No system is too small to adapt to cook-chill.

38. 5. Sous vide
Method of production, storage and
regeneration utilizing principle of
sealed vacuum to control and
preserve the quality of processed
foods.
Individual portions of prepared
food are placed in a special plastic
pouches.

39. 5. Sous vide
Sous-vide is a form of cook-chill: a
combination of vacuum sealing in
plastic pouches, cooking by steam
and then rapidly cooking and
chilling. The objective is to
rationalise kitchen procedures
without having a detrimental effect
on the quality of individual dishes.
Vacuum pressures are as important
as the cooking temperatures with
regard to weight loss and heat
absorption. The highest temperature
used in sous-vide cooking is 100°C
(212°F) and 1000 millibars is the
minimum amount of vacuum
pressure used.

40. 5. Sous vide
As there is no oxidation or discoloration
it is ideal for conserving fruits, such as
apples and pears, for example pears in
red wine, fruits in syrup. When
preparing meats in sauces the meat is
pre-blanched and then added to the
completed sauce.
Sous-vide is a combination of
vacuum sealing, tightly controlled en
papillote cooking and rapid chilling.
Potential users are brasseries, wine
bars, airlines, private hospitals and
function foodservice operators seeking
to provide top quality with portion
convenience.

42. Sous vide (Soo Veed)
1. Pre-preparation
2. Preparation (Portioning)
3. Vacuum conservation (Air extraction) Freezing
4. Vacuum Cooking (-5oC w/in 90 mins
5. Blast Chilling (0oC +3oC w/in 90 mins)
Deep Freeze
6. Chill Store (0oC +3oC ) -18oC
Max 8 weeks
(6-21 days)
7. Regeneration (65oC ) Defrost
8. Service

43. The advantages of the sous-vide process are:
Long shelf-life, up to 21 days if refrigerated.
Ability to produce meals in advance means better deployment of staff and skills.
Vacuum-packed foods can be mixed in cold store without the risk of cross-contamination.
Reduces labour costs at point of service.
Beneficial cooking effects on certain foods, especially moulded items and pates. Reduced weight loss on
meat joints.
Full flavour and texture are retained as food cook in its own juices.
Economises on ingredients(less butter, marinade).
Makes pre-cooking a possibility for a la carte menus.
Inexpensive regeneration.
Allows a small operation to set up bulk production.
Facilitates portion control and uniformity of standards.
Has a tenderizing effect on tougher cuts of meat and matures game without dehydration.

44. Its disadvantages are:
Extra cost of vacuum pouches and vacuum-packing machine.
Unsuitable for some meats (for example, fillet steak) and vegetables which
absorb colour.
All portion in a batch must be identically sized to ensure even results.
Most dishes require twice the conventional cooking time.
Unsuitable for large joints as chilling time exceeds 90 minutes.
Complete meals (for example, meat and two vegetables) not feasible- the
meat com-ponent needs to be cooked and stored in separate bags.
Extremely tight management and hygiene controls are imperative.
Potentially adverse customer reaction (boil-in-the-bag syndrome).

45. Methods of Food Production

46. Methods of Food Production

47. Beverage Production Methods
Beverage is used to describe both alcoholic and non-
alcoholic drinks
Non-alcoholic beverages fall into the categories of raw and
semi-prepared product, and the alcoholic that are in the
main already fully prepared

48. 1. RAW beverages
These are beverage product that are required a higher
degree of preparation before being served to the
customer.
Example such as Tea, Coffee, Cocoa

49. 2. Semi-prepared beverage
These product do not need to
be prepared from the raw
product state, but neither are
they ready-to-serve
Example are Fruit cordials
which required the additional
of water; ice and cocktails
may included in this
categories

50. 3. Fully prepared beverages
These product
requiring virtually no
preparation before
served to the
customer
Example bottles fruit
juice, spirit, wine