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1
Food Service Food Service
SystemsSystems
Carmel LazarusNutrition Manager & Consultant Dietitian
Email: [email protected] Ph: 0416482199
February 2008 University of SydneyAcknowledgements: Karen Walton/Associate Professor Peter Williams/Maria
Kokkinakos
ObjectivesObjectives
�� Understand the different types of food Understand the different types of food
production and distribution systemsproduction and distribution systems
�� Recognise the different cook chill systems Recognise the different cook chill systems
availableavailable
�� Understand the advantages and Understand the advantages and
disadvantages of different production and disadvantages of different production and
distribution systemsdistribution systems
Food Service SystemsFood Service Systems
Williams, PG. Journal of the American Dietetic Association 1996; 96(5): p491
Cook Fresh, Cook/Hot hold, Cook Fresh, Cook/Hot hold,
Cook ServeCook Serve
� Advantages
� ‘In house’ quality control
� Less specialised equipment
� Less prepared storage
� Regional buys
� Disadvantages
� Daily, busy meal times
� Workloads vary� Production occurs
over the whole day, every day
Foods are prepared > Held for a short time > Served
Cook FreshCook Fresh
Salads, sandwiches, fresh/cold dairy desserts also in cook chill systems
Cook ChillCook Chill
� Advantages
� Uniform workflow� Menu variety� Reduced
production costs� 5 day production� Area wide menus � Quality control
� Disadvantages
� Specialised equipment
� Storage requirements� Some recipes aren’t
suited� Some foods not
suitable - grills
Foods are prepared > Chilled > Hot or Cold Plating/Retherm
2
EquipmentEquipment
Short shelf life
EquipmentEquipment
Long shelf life
Cook Chill Cook Chill Cook Chill Delivery SystemsCook Chill Delivery Systems
Cook Chill Cook Chill (Bulk heating, hot plating)(Bulk heating, hot plating)
Cook ChillCook Chill(Cold plating, (Cold plating,
rethermretherm))
Food Service SystemsFood Service Systems
Williams, PG. Journal of the American Dietetic Association 1996; 96(5): p491
3
Cook FreezeCook Freeze
� Advantages
� As for cook chill
� Disadvantages
� As for cook chill� Recipe modification
re: thickeners� Thawing step
Foods are prepared > Frozen > Hot or Cold Plating/Retherm
512Combination
422913
186
12
5Cook-chill- external- internal
548193Cook fresh
2001(n=93)
1993(n=179)
1984(n=270)
Food service systems in NSW Food service systems in NSW
hospitals (%)hospitals (%)
Mibey R, Williams P. Food Service Technology 2002; 2:95-103
Food service systems in NSW
hospitals (%)
100100100100Total
9451Combination
1691312Int Cook chill
4711296Ext Cook chill
29775481Cook fresh
2001100beds +
2001<100 beds
2001All
1993All
System
Mibey R, Williams P. Food Service Technology 2002; 2:95-103
Manager’s satisfaction with their foodservice system Mean rating
(1 = very dissatisfied; 10=very satisfied)
5.9**8.1All
5.87.0250+
5.6*7.9100-249
6.28.350-99
7.18.025-49
8.08.70-24
Cook ChillCook FreshHospital size (beds)
Mibey & Williams Food Service Technology 2002;2:95-103
Meal plating location – % NSW hospitals
139114Decentralised
87918996Centralised
2001100+ beds
2001<100 beds
2001All
1993AllLocation
Mibey & Williams Food Service Technology 2002;2:95-103
Meal delivery systems% NSW hospitals 2001
21.0Total
1.9Conduction heating
3.8Microwave ovens
4.8Infra-red ovens
10.5Convection ovens
Chilled or Frozen systems
79.1Total
1.9Heated bulk food trolleys
4.7Hot and cold delivery cart
14.3Plate cover only
20.9Heated pellet
34.5Insulated cover and base
Hot delivery systems
Mibey & Williams Food Service Technology 2002;2:95-103
4
St Vincent’s CampusSt Vincent’s Campus
SVPH Kitchen
Mental Health
Palliative care & Rehab
D & A
Public Hospital
Delivered in Bulk (heated)Plated on site
Delivered in Bulk HeatedPlated on site
Delivered in Bulk heated using a van
Plated on Site
Centrally platedDelivered in heated and
Refrigerated trolleys
Delivered in bulk
Plated on site
Distribution SystemsDistribution Systems
�� Centralised PlatingCentralised Plating
�� Hot metalHot metal
�� Wax pellet in baseWax pellet in base
�� Insulated plate base & coverInsulated plate base & cover
�� Insulated trayInsulated tray
�� Trolley cart with heat/refrigerationTrolley cart with heat/refrigeration
�� Decentralised PlatingDecentralised Plating
�� Bulk food in chilled/heated trolleysBulk food in chilled/heated trolleys
�� Bulk food in insulated containersBulk food in insulated containers
�� Frozen/chilled food distributedFrozen/chilled food distributed
Distribution Systems cont.Distribution Systems cont.
�� Semi centralised Semi centralised –– food plated centrally and food plated centrally and
distributed for reheatingdistributed for reheating
�� Central tray settingCentral tray setting
�� Decentralised heatingDecentralised heating
�� Specialised TrolleysSpecialised Trolleys
Centralised SystemCentralised System�� AdvantagesAdvantages
�� Labour savingLabour saving
�� Allows meal checking/staff supervisionAllows meal checking/staff supervision
�� Economies of space and equipmentEconomies of space and equipment
�� Saving in overheads Saving in overheads –– maintenance, fuel, cleaningmaintenance, fuel, cleaning
�� Allows batch cookingAllows batch cooking
�� Reduced food wasteReduced food waste
�� Reduced noise on wardsReduced noise on wards
�� Improve menu varietyImprove menu variety
�� DisadvantagesDisadvantages�� More pressure on staff at meal periodsMore pressure on staff at meal periods
�� Must stagger meal hrsMust stagger meal hrs
�� Issues with communication between ward and kitchenIssues with communication between ward and kitchen
�� Physical location of some wards impacts on meal aestheticsPhysical location of some wards impacts on meal aesthetics
Decentralised SystemDecentralised System
�� AdvantagesAdvantages�� Improve motivation/job satisfaction as FS personnel closer to coImprove motivation/job satisfaction as FS personnel closer to consumernsumer
�� Allows last minute changes if food plated in bulk, not for Allows last minute changes if food plated in bulk, not for preplatedpreplated mealsmeals
�� Breaks job tasks down into smaller units so easier to cope withBreaks job tasks down into smaller units so easier to cope with
�� DisadvantagesDisadvantages
�� Difficult to superviseDifficult to supervise
�� Food wastageFood wastage
�� Possible reduction in quality if distributed hot/Physical Possible reduction in quality if distributed hot/Physical
location of some wards impacts on meal aestheticslocation of some wards impacts on meal aesthetics
TrendsTrends
�� Outsourcing Food ProductionOutsourcing Food Production
�� Room Service Room Service
�� Retail Outlets in Hospitals Retail Outlets in Hospitals
�� McCafeMcCafe RPAH,RPAH,
�� Gloria Jeans RNSHGloria Jeans RNSH
5
Food Service SystemsFood Service Systems
� Cook Fresh� Cook Chill� Cook Freeze
� Advantages and disadvantages
� Types of equipment
NUTRIENT LOSSESNUTRIENT LOSSES
ObjectivesObjectives
��Understand the how different cooking Understand the how different cooking
and preparation methods affect the and preparation methods affect the
nutrient content of foodsnutrient content of foods
Nutrient lossesNutrient losses
Natural vs ProcessedNatural vs Processed
• Climate• Soil• Handling• Maturity• Feeding regimes
(for animals)• Genetic
• Preparation, milling• Heating• Drying• Chilling• Freezing• Irradiation• Packaging• Storage
Why processWhy process foods?foods?
1. Raw foods are perishable. Processed to preserve, pack or for storage (e.g. canned foods).
2. To produce a desired product (e.g. baked goods).
3. To prepare food for service.
Nutrients can be destroyed when food is processed
due to:
• Sensitivity to the pH of the solvent• Oxygen• Heat • Light and/or any combination.
6 processing principles that 6 processing principles that
preservepreserve
1. Removing moisture (e.g. drying)
2. Treating with heat (e.g. pasteurisation, cook)
3. Cold temperature (e.g. fridge, freezer)
4. Acidity control
5. Chemical additives
6. Irradiation
6
Effects of ProcessingEffects of Processing
Positive vs NegativePositive vs Negative
•• Anti-digestive factorsmay be destroyed
• Increased starchdigestibility
• Bioavailability increased
• Reduced microbial load
• Addition of antioxidants
• Reduction of heat sensitive vitamins
• Vitamins & minerals leached
• Reduced availability of some minerals and amino acids
Stability of nutrientsStability of nutrients
Karmas, E & Harris, RS. 1988, p4
Stability of nutrientsStability of nutrients
• Losses of 60-100% (Unstable)
Vitamin C, folate, biotin, niacin, riboflavin, thiamin
• Losses of 20-60% (Moderately stable)
Vitamin A, B6, D, E, pantothenic acid
• Losses of < 20% (Stable)
Minerals, Amino Acids, Fatty Acids, Vitamins B12and K
Critical nutrientsCritical nutrients
• Vitamins
Vitamins A, B6, C, thiamin, riboflavin and folate Vitamin C and folate most unstable
•• MineralsMinerals
Iron, zinc and calcium
• Dietary fibre
Primary sources of nutrient Primary sources of nutrient
losseslosses
Animal products
• Thaw drip
• Cooking drip
• Leaching
• Cooking & holding losses
Plant products
• Trimming, slicing, soaking
• Leaching
• Heat losses
• Storage
• Reheating
Processing steps in large scale Processing steps in large scale
food servicefood service
• Purchasing
• Storage
• Preparation
• Cooking
• Texture modification
• Chilling
• Chilled storage
• Reheating
• Hot holding
7
Processing steps and lossesProcessing steps and losses
Purchasing (fresh*/frozen/canned*)• Can occur with any type. Greater vitamin loss with canned,
although ‘fresh’ depends on storage time. (e.g. Spinach can lose >50% Vitamin C if at 20°C for 2 days).
• Drying causes significant losses, especially as more water is removed.
Storage• Depends on the time, temperature* and the stability of
temperature.• Frozen & canned products can continue to lose nutrients
(e.g. Vitamin C) in storage, but lower than the initial processing losses.
*Significant loss is possible
Processing steps and lossesProcessing steps and losses
Preparation
• Thawing meat can result in significant vitamin losses, especially if in water. Using the fridge or microwave is best.
• Trimming fruits and vegetables increases losses (e.g. oxidation).
• Soaking* also enhances losses (e.g. leaching). Aim to soak or wash for a short time to minimise loss. (Current trend is to utilise pre-prepared salads etc.)
Processing steps and lossesProcessing steps and losses
Cooking** Most losses in this stage• Boiling causes greater losses than steaming (Consider
water volume used).• Grill & roasting have smaller losses than braising.• Microwaving, stir frying & steaming seem similar when
using with minimal water.• Baking/frying no significant leaching losses, but greater
vitamin destruction due to the high temperatures.
Chilling• Small losses if chilling is rapid (within 2hrs). Significant
losses if extended (6hrs)*. IHHC Guidelines recommend within 1.5hrs for a gastronorm tray of food.
Processing steps and lossesProcessing steps and lossesChilled storage• Vitamin C is most labile; has a linear loss with time.
Speculation about greater loss in long term cook chill, but lack of 02 may influence.
• Overall, losses still lower in chilled storage, than with hot holding.
Reheating� Smaller loss with individual microwaving.� Large scale food service, usually mass reheating.� Limited data, appears loss is greater when chilled food
heated in bulk, rather than individually- due to the time involved?
� There appears to be no significant differences in losses in reheating, considering infrared, convection, conduction..
Vitamin C loss in chilled storageVitamin C loss in chilled storage
Williams, PG. Journal of the American Dietetic Association 1996; 96(5): p492
Processing steps and lossesProcessing steps and losses
Hot holding**
• Significant losses. Even 30 minutes can cause losses.
• Hot holding should be kept to <90 minutes.
8
Williams, PG et al. 1995: p545
Vitamin C and folate in cookVitamin C and folate in cook--chill chill
and cook/hotand cook/hot--hold systemshold systems
Williams, PG. 1994; p164
Vitamin C and folate in cookVitamin C and folate in cook--chill chill
and cook/hotand cook/hot--hold systemshold systems
• After 1 day chilled storage, then reheating results in a similar effect on Vitamin C to the following hot holding times;• 91 minutes for Vitamin C• 87 minutes for 5MeTHF
• Plated and reheated after 3 days of being in chilled storagewould retain ~28% Vitamin C & 58% 5MeTHF.
• In contrast, hot hold for 2hrs resulted in the retention of ~40.3% Vitamin C and 67.7% 5MeTHF.
• If hot hold <90 minutes, vitamin retention is better in a cook-serve than in a cook-chill system.
Williams, PG et al. 1995
Effects of processing in hospital Effects of processing in hospital
cateringcatering
West, A et al. 1998; p285
• Vitamin C losses increase over the 5 days of storage.• Losses increase with hot holding time. ‘Ideal’ 30 mins.• Awareness of where losses occur, enables better planning.
Loss of Vitamin B6 in hot Loss of Vitamin B6 in hot
holdingholding
• Riboflavin & niacin fairly stable
• Thiamin usually less than 10% loss, for up to 2hrs
• Vitamin C is lost rapidly
• Vitamin B6 is lost• Minimum loss of 10% after 1hr• Up to 40% at 3hrs
Williams, PG, 1996
Canned, Frozen and FreshCanned, Frozen and Fresh
Percentage losses after canningPercentage losses after canning
Nutrient Folacin B1 B2 B3 B6 CAsparagus 75.2 66.7 55 46.6 64 54.5
Carrot 58.8 66.7 60 33.3 80 75
Corn 72.5 80 58.3 47.1 0 58.3
Tomato 53.75 16.7 25 0 - 26.1
Karmas, E & Harris, RS. 1988: p344
9
Percent carotene retention in Percent carotene retention in
stored canned foodsstored canned foodsTemperature 10°C 10°C 18°C 27°C
Months 12 24 24 24
Apricots 94 91 84 76
Carrots 94 90 95 91
Peaches 95 75 64 63
Spinach 91 80 80 81
Tomatoes 94 75 75 74Karmas, E & Harris, RS. 1988: p345-347
Percent ascorbic acid retention Percent ascorbic acid retention
in stored canned foodsin stored canned foodsTemperature 10°C 10°C 18°C 27°C
Months 12 24 24 24
Apricots 96 94 90 56
Pineapple 100 83 78 53
Peaches 98 98 80 53
Asparagus (Gr) 97 93 91 86
Beans (Gr) 92 88 81 74Karmas, E & Harris, RS. 1988: p345-347
Vitamin C in fresh & frozen vegetables
Favell, DJ. Food Chemistry, 1998: p59-64
Peas, Broccoli, Green beans, Spinach, Carrots
Day 0 Garden fresh
Day 3 Ambient Day 3-7 Ambient
Day 2-3 Chilled Day 3-7 Chilled
Day 3-7 Chilled/Ambient
Peas
Peas
0
5101520253035
Garde
n fre
sh
Day 3 A
mbie
nt
Day 3-7
Am
bient
Day 2-3
Chil
led
Day 3-7
Chil
led
Day 3-7
Am
bient
/Chil
led
Froze
n Initia
l
Froze
n 12 m
onths
Type and time of storage
mg
/100g
vit
am
in C
pre
sen
t
Broccoli
Broccoli
0102030405060708090
Garde
n fre
sh
Day 3 A
mbient
Day 3-
7 Am
bien
t
Day 2-
3 Chil
led
Day 3-
7 Chil
led
Day 3-
7 Am
bien
t/Chil
led
Froze
n Initia
l
Froze
n 12 m
onths
Type and time of storage
mg
/100g
vit
am
in C
pre
sen
t
Spinach
Spinach
0
5
10
15
20
25
30
Garde
n fre
sh
Day 3 A
mbient
Day 3-
7 Am
bien
t
Day 2-3
Chil
led
Day 3-7
Chil
led
Day 3-7
Am
bien
t/Chil
led
Froze
n Initia
l
Froze
n 12 m
onths
Type and time of storage
mg/1
00g v
itam
in C
pre
sen
t
10
Thiamin content of frozen steak Thiamin content of frozen steak (mg/100g)(mg/100g)
Constant Fluctuating
Temp (+ 1°C) Temp (+ 5°C)
Initial 3.0 3.0
-10°C 2.8 1.8
-20°C 2.9 2.1
-30°C 3.0 2.6
Karmas, E & Harris, RS. 1988: p561Karmas, E & Harris, RS. 1988, p308
Method of cooking broccoli vs Method of cooking broccoli vs
phenolic compound contentsphenolic compound contents• Compared the influence of
cooking methods on phenols in broccoli. 150g broccoli, 150ml water
• (A) High pressure 3 min• (B) Low pressure 5 min• (C) Steaming 3.5 min• (D) Microwaving 5 min
Microwave > Highest losses? Overcooked
Steaming superior- short time & nowater contact
Vallejo, F et al. 2003: p1515
IrradiationIrradiation• Uses
• Controls insects in spices, herbs, nuts & grains
• To reduce the level of bacteria in meat• Minimise sprouting in fruits & vegetables
• Influence on nutrition• Similar vitamin losses to heat processing• No significant impact on carbohydrates,
protein and minerals• May increase fat oxidation
Further research required on phytochemicals & antioxidants
Effect of processing on major flavonoids
in onions
� Significant (50%) reduction with peeling & chopping
� 90% of quercetin (flavonoid) is in the 1st & 2nd
layers
� Fairly heat stable thereafter
Ewald, C et al. Food Chemistry, 1999: p231-235
Blanching & freezing on bioactive
compounds in vegetables
� 20-30% losses of antioxidant activity & total phenolics
� Up to 30% vitamin C lost with blanching
� Up to 50% folate lost
� Carotenoids & sterols stable
Puupponen-Pimia, R et al. Journal of the Science of Food and Agriculture, 2003: p1389-1402
11
In Summary
Recommendations to maximise nutrient retention
Dry Goods
� Store dry goods at <20°C
Fresh goods
� Minimise the time stored� Shop 2-3 times per week, if possible, to optimise
the retention of the nutrient value and appearance� Protect from heat and light�Stable refrigeration temperature� Always wash before use
Recommendations
Frozen foods
� Keep freezer temperatures stable� Thaw in the refrigerator
Preparation
� Cut foods just prior to service
Cooking
� Cook larger vegetable portions� Restrict the time for ‘hot holding’� Use minimal water to cook vegetables� Consider steaming, microwaving and stir frying
Recommendations
� Know where losses occur and plan accordingly
� Include a variety of foods in your day that are rich in critical nutrients (e.g. fresh fruit for vitamin C, legumes andgreen leafy vegetables for folate)
ReferencesReferencesEwald, C, Fjelkner-Modig, S, Johansson, K, Sjöholm, I and Åkesson, B. Effect of processing on major flavonoids in processed onions, green beans, and peas. Food Chemistry 1999; 64(2): p231-235
Favell, DJ. A comparison of the vitamin C content of fresh and frozen vegetables. Food Chemistry 1998; 62(1): p59-64
Hunt, C. Vitamins in institutional feeding. Journal of Micronutrient Analysis 1990; 7:p193-206
Karmas, E & Harris, RS. Nutritional Evaluation of Food Processing (3rd edition). New York: Van Nostrand Reinhold Company Inc; 1988.
Light N & Walker A . Cook-Chill Catering Technology and Management. Elsevier Applied Science: Barking; 1990.
Mibey R & Williams P. Food service trends in New South Wales hospitals, 1993-2001. Food Service Technology 2002; 2:95-103.
Puupponen-Pimiä, R, Häkkinen, S.T, Aarni, M, Suortti, T, Lampi, A.M, Eurola, M, Piironen, V, Nuutila, A.M, Oksman-Caldentey, K.M. Blanching and long-term freezing affect various bioactive compounds of vegetables in different ways. Journal of the Science of Food and Agriculture 2003: 83(14): p1389-1402
Puckett, RP. Food Service Manual for Health Care Institutions (3rd edition). San Francisco: Jossey-Bass; 2004.
ReferencesReferences
Vallejo, F, Tomas-Barberan, FA and Garcia-Viguera, C. Phenolic compound contents inedible parts of broccoli inflorescences after domestic cooking. Journal of Food ScienceAgriculture 2003; 30: p1511-1516
West, A, Walker, A and Lawson, J. The effects of food processing in hospital cateringsystems. Conference Proceedings of ICCAS 98-Culinary Arts and Science II Global andNational Perspectives 1998: p283-289
Payne-Palacio J, Theis M. West & Wood’s Introduction to Foodservice (9th ed). PrenticeHall; 2001.
Williams, PG. Vitamin retention in cook/chill and cook/hot-hold hospital foodservices.Journal of the American Dietetic Association 1996; 96(5): p490-503
Williams, PG, Ross, H. and Brand-Miller, JC. Ascorbic acid and 5-methyl-tetrahydrofolatelosses in vegetables with cook/chill or cook/hot-hold foodservice systems. Journal ofFood Science 1995; 60:p541-546
Williams, PG. Food in Hospitals. PhD thesis. 1994