Kitchens of the Future
By Lisa White, Contributing Editor -- Foodservice Equipment & Supplies, 7/1/2006
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| Don't miss: An Update on the NAFEM Data Protocol. |
Technology is not always created equal. For instance, although most operators currently benefit from sophisticated point-of-sale systems, there has been less innovation on the foodservice equipment side.
“The sad thing is, automobiles have more computer automation than most commercial kitchens,” says Richard Young, director of education and senior engineer at the Food Service Technology Center (FSTC), a San Ramon, Calif.-based industry leader in commercial kitchen energy efficiency and appliance performance testing.
Yet, many in the industry predict this is about to change. “The biggest driving force in emerging equipment technology is energy use,” says Bob Bruce, director of engineering at Chanhassen, Minn.-based Control Products. “Everyone is trying to reduce costs and use less energy. Today’s kitchen technologies also are all about taking labor out of the picture. Operators want to produce better quality products using less labor and energy.”
Fortunately, energy savings methods have come a long way since their creation in the 1970s. At that time, energy management systems were a burden to operate and install. The success of these devices also was dependent on workers being conscientious enough to use them properly. “They then became expensive boxes on the wall,” Young says.
In those days, energy was a smaller percentage of restaurants’ operating costs. As a result, lights were left on constantly, equipment was kept running when not in use and employees would think nothing of propping open refrigerator doors for long periods. “Really good managers would turn off the lights and shut refrigerator doors, but restaurants were fully reliant on humans to run the energy systems,” Young says.
Due to the expense in building restaurants, most operators back then would balk at adding an extra $10,000 to $12,000 for more energy efficiency systems. “There were questions about the advantages of these devices and the return on investment, so most operators left these matters to their employees to do what they could,” Young says.
In the late 1990s, Young adds, “everyone finally woke up, particularly the big chains.” These companies realized that, with the growing number of restaurant outlets around the world, they needed some method of accountability. It was soon determined that the first piece of the puzzle would be creating a common language in which all equipment systems could communicate. This signaled the beginning of what would be known as the NAFEM Data Protocol. (For more information on this topic, refer to the NDP article on page 38.)
At the beginning, everyone had high hopes that this project would come together quickly and easily. A couple of companies began working on technologies that many thought would answer the industry’s needs. Equipment was becoming digitally controlled and 25-cent computer chips were being installed on new lines so they could communicate using an Ethernet. Then the technology market fell apart. “This is when everyone dropped the ball, chains became more competitive and the technology guys were told to put the kabash on everything,” Young says. The focus on a universal protocol, what many agreed was the key to developing smart kitchens, was put on hold.
Fast-forward to today, and it is obvious that this vision of a smart kitchen is taking shape. Operators and manufacturers alike are actively pursuing the protocol, as more technology is being incorporated into equipment and foodservice operations. And, as though it came full circle, the main focus now is on conserving energy.
Increasing Energy Efficiency
At the forefront of this movement are California’s gas and electric utility providers, which offer operators rebates for using energy-efficient equipment. By employing energy-efficient combi ovens, steamers, griddles, ice machines, refrigerators, freezers and hot-holding cabinets, customers receive rebates between $125 and $1,000, says David Zabrowski, senior research engineer at San Ramon, Calif.-based Fisher Nickel, an engineering consulting firm specializing in the foodservice industry and operator of the FSTC.
The Boston-based Consortium for Energy Efficiency (CEE) works with gas and electric utility companies across the country that administer energy efficiency programs and provide incentives for those using more efficient equipment. Ted Jones, senior program manager, says his firm developed a national initiative to measure the efficiency levels of commercial foodservice equipment. “For equipment manufacturers, this will provide consistency across the country for measuring energy efficiency,” he says.
Energy Star, a designation supported by the government’s Environmental Protection Agency (EPA) to help protect the environment through energy efficiency, has become a familiar designation with residential appliances, but is new to the commercial foodservice equipment industry. Instead of a rating, equipment labeled with the Energy Star logo has been specified in the top 25 percent for energy efficiency compared to other units of its type.
CEE worked with Energy Star to develop the specifications for equipment to carry the label. The company also worked in conjunction with equipment manufacturers to ensure that the specifications were accurate. “None of the specifications or equipment we’re looking at are high-tech,” Jones says. “In fact, a lot of it applies to existing technology that helps makes appliances more energy-efficient.”
One of the latest introductions under the Energy Star banner is water-efficient dishwashers. “Water reduction is a big deal because it contributes to total energy cost,” says Rick Cartwright, director of warewash engineering at Troy, Ohio-based Hobart Corp.
Because many large restaurant chains are sensitive to energy costs, Cartwright believes more operators will seek energy-efficient equipment in the years ahead. “Energy costs are driving a lot of innovative ideas in the industry. People are trying to find ways to lower the cost of energy and water to offset capital costs. Because utilities are partnering together, it has made a big splash,” he says.
In terms of cost savings garnered from using Energy Star equipment, Jones says these can be fairly significant, but are dependent on each region’s energy costs. “There are some nifty calculators online that people can use,” he says.
Cooking systems continue to make news on the energy efficiency front. “One of the more exciting developments is a new broiler design that Burger King is testing in 10 corporate stores. The conveyor system not only offers faster product turnaround, but also decreases energy consumption between 25 percent and 50 percent. Plus, it is designed with less parts so it is easier to clean and maintain,” Zabrowski says.
Making the Grade
Another rollout in conjunction with Burger King’s new cooking platform is a product management system that automatically calls levels, provides a list of products to cook and grades the kitchen staff’s performance.
“The system is designed to help maintain product quality, minimize waste and ensure that there is enough product to meet the speed of service requirements,” says Mark Finck, Burger King’s equipment engineer and head of research and development worldwide. “Its main function is to provide a consolidated list of products for the staff to cook or discard.”
Using a display in the back of the kitchen, the PC-compatible program informs the staff what and when to cook based on sales forecasts it downloads from the point-of-sale system. The system records and recalculates data every 15 minutes, reducing or increasing the volume needed based on the number of food orders.
The system automatically knows how long it takes to prepare food and how long it can be held. “The system knows it should receive food in a certain period of time. If food is not produced in the time allotted, the system gives a negative strike. It also knows that a Whopper will expire in five minutes and will send a signal to the user. If food is not discarded when it says it should be, users will get graded negatively,” Finck says.
Because the system provides Burger King with a grade on food quality, the chain switched to a grading system that helps assess its managers. “When a manager logs in for the day, they turn the system on and type in their name and time of service. The manager is then graded by their ability to maintain product quality throughout the day,” Finck says.
The comprehensive data provided by this technology, which includes the manager’s information, alpha grade and details on cooking and quality performance, can be downloaded by computer and viewed on the internet. With this system, chain operators are able to take quantitative measures out of multiple restaurant locations and view the results from a centralized location.
Since incorporating this system, Burger King customers reported a significant jump in sandwich quality, Finck reports.
Accelerated and Automatic Cooking
Along with enhanced quality and improved energy efficiency, speed of service is a key driver in the evolution of the smart kitchen. One new technology impacting the industry is accelerated cooking.
“When you look at the QSR [quick-service restaurant] segment, the bottlenecks for speedy service are extensive cooking times,” says Rick Caron, chief technology officer for Enodis, a New Port Richey, Fla.-based equipment manufacturer. “For this reason, most fast-food restaurants are required to cook and hold food [to accommodate changes in customer volume]. Accelerated cooking allows operators to offer cooked-to-order dishes, while maintaining high product quality and freshness standards.”
Operators can choose from a number of accelerated cooking ovens, including countertop, conveyor and combis. These units superimpose two to three different heat-transfer methods simultaneously, resulting in cooking speeds that are 10 to 15 times faster than conventional methods. “To put it in perspective, a rack of lamb can be cooked in 90 seconds using this method,” Caron says. Computer-controlled cooking modes manage the heat application, which provides baking, broiling, roasting, toasting or oven crisp cooking capabilities.
Integrating the kitchen by linking two appliances together, such as integrating refrigerated bases with accelerated cooking stations, can save space, energy and labor. The kitchen of the future will integrate electronic controls, cooking technology and refrigeration innovations with building control and ventilation systems, predicts Dean Landeche, Enodis vice president of marketing.
Ovens in these kitchens will be more automatic and able to accept downloadable information like a computer. Operators will simply press a button and the equipment will take over. Space constraints would no longer be an issue for kitchens offering this advanced technology. With a smaller footprint, this equipment would work more effectively, offer greater efficiencies and allow for more flexibility in location size. “For example, if a more effective grill can reduce cook time by 20 to 30 percent, operators can gain speed, while saving on space and energy,” Landeche says.
A more compact and efficient kitchen also impacts labor. According to Caron, the preparation of one menu item may require a worker to turn 15 to 20 times, with many wasted steps. “Combining all of the kitchen elements into one station minimizes steps,” he says, adding that this arrangement also can reduce energy consumption from 10 percent to 50 percent.
Another newer technology is an automatic system that finishes cold pre-plated food in less than 10 minutes. A probe measures food temperatures, compensating for the climate and cooking process, so quality is not compromised.
Ventilation on Demand
Recent ventilation regulations by the International Code Council’s 2006 Edition, Section 507.2.1.1 requiring hoods to operate while cooking equipment is running, have spurred a number of innovations. Although the technology used in these systems is not new, it has now become less cost-prohibitive.
One ventilation control technology uses an infrared beam running across the hood that responds to vapors or steam. Temperature and optic sensors monitor equipment’s heat and smoke load, automatically varying the fan speed when necessary. A bar graph depicts the percentage of the fan’s speed. Currently, Brinker International has specified the system for its Chili’s and Macaroni Grill restaurants.
Controlling ventilation with this type of system automatically provides energy savings by keeping conditioned air in the kitchen rather than circulating it out with continuous fan operation.
What the Future Holds
Experts and innovators predict a continued focus on energy-saving technology in the coming years. “In some cases, energy costs can total 25 to 30 percent of an operator’s expenses. We are working on nugget machines where every drop of water gets turned into ice. Typically, 30 percent of water from these units goes down the drain. Operating 30 percent more efficiently saves on electricity and water costs, adding to a restaurant’s bottom line,” Caron says.
Temperature monitoring systems that collect data using wireless technology are entering testing phases. “There has been a lot of talk about collecting data from equipment, but we think there is a real future in collecting data and tools from the workforce,” says Roberta Salerno, president and CEO of Integrated Control Corp. (ICC), based in Huntington, N.Y.
Looking ahead, Young sees automated kitchens that don’t require humans to turn equipment on or set temperatures. “Although the industry is starting to do some point-of-sale automation and adding LED panels that list food orders, the big thing missing is the technology that ties it all together,” he says. “The components are the easy part. The hard part is coming up with the software that automates the kitchen and acts as the puppetmaster.”
Young recalls a trade show booth that featured an IBM robot programmed to work in the kitchen. It was able to cook pancakes on a griddle and make french fries in a fryer. The robot had handles so it could flip the pancakes and lift the fryer baskets. “I watched it cook and it did a good job,” he says.
“There area lot of benefits with this, and it gave a hint as to where kitchens can go in the future. A robot doesn’t have a closing time. They can clean all night. They can’t get burned, so you can have cooking equipment situated together in a tighter space. But the downside is cooking is not a uniform task and every kitchen is different.”
Rather than automating a kitchen, Young says it makes more sense to concentrate on increasing its energy efficiency. “An energy management system is more practical. These days, it has become more important for operators to save money on water, gas and electricity,” he says.
Landeche agrees, saying the key is not to focus on technology for technology’s sake. “Instead, we should be concentrating on things we can change that don’t take years to develop. We need to take advantage of technology that creates results,” he says.
Whether the kitchens of the future are fully automated or offer the utmost in energy efficiency, as foodservice equipment becomes more technologically advanced, the industry is sure to see big changes in the years ahead.
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