Looking
to improve the efficiency of your candy kitchen? Rethinking the layout of your
kitchen is a great place to start. RCI member Greg Power with Las Olas
Confections and Snacks shares tips, plus which areas to focus on for the most
impact in this week’s post.
When
reviewing your production layout, first, take measurements of your equipment
and space. Draw a diagram of your space on paper; create scale cut outs of equipment
and other movable items so you can move the items around easily. This will
allow you to visualize the best placement of your equipment and help with
layout options to maximize production and product flow.
Your production space should be enclosed and it should not open directly to outside areas; this will help with security and reduce exposure to outside elements. Smooth, walls, tile cove base and sealed concrete floors or tile flooring are all preferred for ease of cleaning and washing down. Storage racks should be off the ground and away from the walls (check for local health codes for how far off the ground and how far away from the walls is required). Any non-food contact equipment that can be stored or installed out of the production area is preferred and may open up additional kitchen space if stored elsewhere. Air compressors, boilers, cleaning equipment, etc. should all be stored away from production.
Production
The
kitchen production area is the beginning of your entire process; which is why outflow
from the kitchen should be smooth and effortless as the product moves to your
production lines. If space permits, your kitchen should be separated, but
adjacent to your slabbing or table room. This setup is the most efficient
process for getting product off of the tables and on your production lines. If
your tables are water-jacket cooled and you have a temperature-controlled cooling
room available (at least 60˚F/15˚C), this will offer the most efficiency for
cooling your products as quickly as possible from batch to production. You want
to remove the heat from the product as fast as possible without sweating it.
Flow
From
slabbing, product should go straight into enrobing or coating. This area should
be as close to the slabbing or cutting area as possible. If you are hand
dipping, multiple stations can be set up adjacent to the slabbing area. From
enrobing or coating, products should flow straight into cooling tunnels then
into the packing area. After packing, product may be stored in a cool, dry
place for several days at 65˚ F/18˚C before transport.
Equipment
If
space permits, avoid turns and curves within the process. Fewer transitions and
handling of product will reduce labor. All equipment should be on legs, stands
or wheels off the floor and away from walls; it should be easily accessible
from all sides for easy cleaning and maintenance.
Production space should be limited to items needed for a specific run, excess equipment, cooling racks and raw materials. Work-in-process can reduce your ability to run efficiently and cause increased labor inefficiencies. Fine tuning some of these areas could have a surprising impact on the efficiency of your team.
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