Cook-Chill
Project Details and Client Highlight List William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale
DENVER Ι PHILADELPHIA Ι SAN FRANCISCO Ι SCOTTSDALE
Food & Beverage Facilities Planning and Design Worldwide
The 1976 Summer Olympic Games – Montreal, Quebec Bill Caruso assisted the food service planning team in developing the feasibility and master planning analyses for the food and beverage services for both of these worldclass athletic events. In the case of Montreal, all facilities were built new. Work encompassed: Evaluation of user/athlete markets Target market demand calculations Effect on security regarding access/egress to food and beverage receiving and marshaling points Menu requirements and their effect on equipment, flow, cook/holding systems and transportational logistics Development of facility mix recommendations Sizing of facilities including main and satellite commissaries Planning and design of all main and satellite commissary units with particular emphasis on: Space and storage analysis Preparation procedures Cooking system review C cook/serve vs. cook-chill vs. cook/freeze Preparation analysis C semi-automated procedures for preparation, including in-house vs. contract baking services Boston University, School of Restaurant Administration – Boston, Massachusetts California Health Care Facility – Stockton, California The California Department of Corrections commissioned WC&A to program and design the largest correctional healthcare facility in the world (a budget of $3 Billion). The program provided phased construction of facilities to support 10,000 medical beds for the California DOC correctional system. The first phase of the project required 3,500 beds of varied acuity levels at the Stockton location. The design provided for a 5,000 sq. ft. warehouse, a central 30,000 sq. ft. state-of-the-art cook/chill production kitchen and multiple food staging areas, multiple satellite re-thermalization pantries (located at medical housing units), and a staff dining area with on-site cooking and serving. The facility is programmed and designed to accommodate meal production for unique medical diets. Clark County School District – Las Vegas, Nevada The largest public School District in the state of Nevada hired William Caruso & Associates as its food facility master plan consultant. Our task was twofold, namely: 1) To assist the architects, engineers and design consultants on a number of ongoing design projects relating to their foodservice programs and plans; 2) To provide a detailed, systematic master plan document which would encompass all aspects of the
William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale
WC&A Cool-Chill Project Details Page |2 district's food service program. This included all 214 existing or planned schools, a central warehouse/commissary facility, a major truck transport fleet, and outlying schools that cover over 10,100 square miles of area that constitute the boundaries of the district. Cornell University – Ithaca, New York Bill Caruso, as principal with a previous firm, completed the detailed master planning for University Dining Services through the year 2010. Work included focus group meetings with staff and students, data analysis and facility/cost estimates for various new and renovated facilities on the Cornell campus. All work was completed on time and within the budgets set out by the University. Dallas County Commissioners Court Facilities – Dallas, Texas WC&A was commissioned to study the impact of a cook/chill food production system implementation into Dallas County's six major correctional holding facilities. A detailed study was completed that suggested development of a central kitchen feeder unit to serve a number of satellite receptor kitchens. Denver Sheriff Department – Central Cook/Chill Production Kitchen Facility – Denver, Colorado WC&A’s commission began by writing a feasibility study for a central cook/chill food production system as part of an expansion of the Denver Justice Center and the Denver County Detention Facility with a goal of production consolidation and potential of economic efficiencies. The study was well received by the City and County of Denver and funded as a special project by the Mayor of Denver. WC&A programmed and designed the central production kitchen, as well as satellite facilities. The production kitchen utilizes the latest cook/chill technology and is sized to produce 18 to 25,000 meals per day. Denver VA Medical Center – Denver, Colorado William Caruso & Associates was commissioned by H+L Architecture and SOM to provide programming and design expertise for the new Veterans Administration Medical Center in Aurora, Colorado. The Hospital will be part of the 75-year-old Fitzsimmons Medical Campus. The facility named "project eagle" will be one of the top VA Medical Centers in the country. It will include 200 medical beds (including an acute care wing), a spine center, Community Living Center (CLC). The spine center and CLC are based on the VA mandate of "Small House/Green House" living centers. The dietary/nutrition services portion of our work included receiving, main production and patient meal service kitchen, food court/servery and retail outlets. The foodservice program will provide state-of-the-art food service complete with the latest in cook/chill technologies and meal on demand "room service".
William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale
WC&A Cool-Chill Project Details Page |3 Fresno Veteran’s Administration Senior Center – Fresno, California William Caruso & Associates developed and designed the new Fresno VA Senior Center in Fresno California. The facility is equipped will minimum to skilled nursing care in a semi-residential setting. The goal of program was to provide a “normal” home-style environment with all of the readily available medical care to enhance the Veteran’s stay experience. WC& A provided design assistance for the site community center commons dining area, the housing kitchens as well as campus cafes. A full commercial laundry with built-in cross contamination free design was provided for campus linen services. The foodservice program will provide state-of-the-art food service complete with the latest in cook/chill technologies. Johnson County Community College – Overland Park, Kansas Kent School District – Kent, Washington WC&A, Inc. planned and designed a 20,000/meal per day central kitchen facility for this high growth school district in the metro-Seattle area. Services include a complete warehouse design including a semi-automated bakery, automated food production utilizing a cook-chill system and automated packaging components. Included in the design planning was a phased design construction plan to accommodate the anticipated growth requirements of the district. This plan minimized initial capital expenditures for the Kent School District. Long Island Jewish/Hillside Medical Center – New Hyde Park, New York* WC&A provided the key direction for the master planning of this major 15,000 sq. ft. central commissary project that called for a complete production facility and system renovation. Major additions to this famous hospital required expanded service to its 800 patients and additional visitors and staff. A complete restructuring of its operating and production systems to include cook-chill technology were implemented, along with a state-of-the-art transportation system to accommodate product transport to remote system operating facilities. Oklahoma State University – Stillwater, Oklahoma Staten Island Hospital – Staten Island, New York Feasibility and master planning analyses were provided to the dietary department of this metropolitan New York health care center. An evaluation and restructuring of an existing cook- -freeze program that had been instituted some five years earlier occurred. Detailed analysis recommended both modification to the production process as well as alterations and redesign of the staff cafeteria, reconstitution, and tray assembly lines as well as the floor galley reheat systems.
William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale
WC&A Cool-Chill Project Details Page |4 University of California at Berkeley – Berkeley, California A complex 550-page planning document for all facets of the food/beverage system of this 35,000-student campus was developed for the University of California-Berkeley. A demand in excess of 150,000 meals per day produced from aging and inadequate facilities required a detailed evaluation of user groups, variable demand by user groups, a new facility introduction that would alter and expand future growth potential, as well as an increased awareness of quality and service requirements for all food and beverage staff. Recommendations included centralization of the system through development of a large cook-chill system central commissary capable of meat cutting, baking, full bulkfood production services, and augmented by a fleet of delivery trucks (both refrigerated and non-refrigerated) to service up to 40 operating units on a daily basis. Detailed product-flow planning using bubble diagrams as instructional material and pert chart scheduling/event sequencing all provided a logical planning guide to this complex project recommendation. A complete operational construction phasing plan also was included to minimize the service interruption developing from transfer of local site production to that of centralized commissary preparation/delivery. Additionally, a number of existing food service kitchen areas were released back for re-use in other areas in favor of new facilities serving a variety of ethnic foods located in a variety of strategic campus population areas . Veteran’s Administration Medical Center – Aurora, Colorado WC&A was commissioned by H+L Architecture and SOM to provide programming and design expertise for the Veterans Administration Medical Center in Aurora, Colorado, which is just outside of Denver. The Hospital is part of the 75-year-old Fitzsimons Medical Campus. The dietary/nutrition services portion of our work included receiving, a main production and patient meal service kitchen, a food court/servery, and retail outlets. The food service program provides state-of-the-art food service complete with the latest in cook/chill technologies. Volunteers of America – Denver, Colorado WC&A, Inc. was commissioned to plan and design the renovation to the central commissary facilities for the Volunteers of America in Denver, Colorado. Projections for VOA's Denver operations estimate a volume of over 4,000 meals per day for the programmable future. Thus, a significant increase in food service production capacities was required. WC&A recommended a cook/chill system be incorporated for both increased production output and increased labor efficiencies. Elements designed into this facility included central warehouse stores for both the City Harvest and Meals-OnWheels programs, a cook/chill production facility utilizing both a tumble cook/chill tank system and a bulk blast system for maximum flexibility, refrigerated storage for temporary staging of finish products, a conveyorized assembly line, bakery, and a ware washing facility designed to accommodate the various types of transport containers.
William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale
WC&A Cool-Chill Project Details Page |5 Washington Department of Corrections – Airway Heights, Washington The state of Washington Department of Corrections commissioned WC&A to plan and develop a "food factory" facility in Eastern Washington to produce food for over 2,000 local inmates and 25,000 statewide inmates. WC&A developed the master plans for this large cook–chill system facility and designed all components ready for operation by the owner. This facility has been lauded as being "on the cutting edge" of technological advancement. Wichita School District Commissary – Wichita, Kansas This school system included in excess of 100 satellite schools spread out over a 25-mile radius. Forty thousand (40,000) school children, plus anticipated outside users, formed the market that utilized the system’s eating facilities, which included: cafeterias, fast food, snack, bars, etc. These units were serviced by a commissary located in a large central services complex on the outskirts of Wichita. Mr. Caruso conducted an evaluation and analysis of this complete system with emphasis on the commissary and the transport/logistics system. Recommendations included a re-structuring of the system with particular emphasis on using industrial engineering expertise and equipment. An automated full-line, state-of-the-art baking operation was developed after an intensive feasibility evaluation determined that in-house production was more cost effective and consistent in high-product quality than production from base mix or developing specification and the costs of an outside baking contract. Additionally, evaluations of fully-automated versus partially-automated produce and central cooking services were analyzed - new equipment was found and tested to increase productivity and ultimately a cook-chill-freeze system recommended for service. Fully automated, overhead staple-goods conveyors were also analyzed versus traditional mobile cart transport systems. The owner ultimately desired the former but because of budgetary considerations, was forced to accept the latter system. The issue of meat cutting and preparation also arose including the options of cutting full sides versus quarter versus trimming versus portion-control. After evaluation of type/style of product demand, labor cost/specialized skills required, transport/delivery/warehousing costs of these products, specialized equipment needed rail systems, humidity and light controlled refrigerated walk-in boxes (and resultant total costs of these) a decision was made to augment portion control with simplified trimming of products. Wisconsin Department of Corrections – Madison, Wisconsin The state of Wisconsin Department of Corrections commissioned WC&A to extensively study the state’s Department of Corrections’ facilities and evaluate the potential for centralized cook–chill systems. Extensive research and data development was accomplished along with schematic design plans to implement a partial centralized system that would support more urbanized facility production needs through centralization. A number of remote Department of Corrections units remained on a selfcontained, traditional cook–serve system.
William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale
WC&A Cool-Chill Project Details Page |6 Yuma District Hospital – Yuma, Colorado WC&A was selected to design the food service facilities for the Yuma District Hospital. This 50-bed rural hospital provides state-of-the-art care in the far reaches of northern Colorado. The food service facilities utilize cook/chill technology and provide the latest in “room service” patient dining. The food service facilities also include a full service café with a “made fresh” to order menu as well as prepackaged items for the “grab-andgo” customer. The laundry facilities include the latest in pass through/barrier type washing equipment to eliminate contamination possibility.
William Caruso and Associates, Inc. • Food & Beverage Facilities Planning and Design Worldwide 8055 East Tufts Ave., Suite 1320 • Denver, CO • 80237 • 303-649-1600 • www.wcarusoassoc.com Denver
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Philadelphia
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San Francisco
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Scottsdale