AU738500B2 - Restaurant food preparation line - Google Patents

Description

RESTAURANT FOOD PREPARATION LINE Background of the Invention Field of the Invention The present invention relates in general to the efficient preparation of a comestible product. In particular, the present invention relates to an improved food preparation line of the type used in a restaurant.

Related Art Restaurants, including quick-service restaurants, typically employ food preparation lines. For example, a common food preparation line is a straight line having several work stations. The workers build a meal as it progresses from a starting end, through several work stations, to a serving end. At the serving end, the end food product can be readied for serving or packaged for take-out or delivery orders. Accordingly, these food preparation lines require many workers and an accompanying large working area.

Prior straight food preparation lines have several additional drawbacks. The preparation lines require o 15 interruptions in the preparation process while being stocked with food product. The typical food preparation line also S• merely prepares the food while others package it for the customers. In addition, the workers commonly must o transfer the food across the relatively large distances between the preparation line and the counter space used to S serve the customers. The long transfer requires more time, can result in food product dropping, and results in larger food preparation areas or decreased seating capacity.

20 Summary of the Invention Accordingly, there is a need for a restaurant which employs a food preparation line of ergonomic construction which requires fewer workers. In addition, there is a need for a food preparation line which allows the food product supply to be maintained without interrupting the workers preparing the food products. There is a further need for a food preparation line which allows the workers preparing the food product to readily package a 25 food product for the customer.

P: OPER\DHM6322-98 rs2.doc-25/06101 -2- In accordance with the invention, there is provided a food preparation line comprising a first section, a second section lying generally normal to the first section, and a third section positioned next to and extending away from the second section at an angle and in the same general direction as the first section, a first inside corner being defined at a juncture between the first section and the second section, a second inside corner being defined at a juncture of the second section and the third section, a heated storage compartment positioned on the first section, a cooled storage compartment positioned on the second section, a heating device being positioned on the first inside corner and a generally open 0 package storage compartment located near an end of the third section, which end is distal of the second section, whereby the packaging stored in the generally open package storage compartment are easily accessed.

In another aspect, there is provided a food preparation line comprising three sections being positioned to form a generally U-shape counter, the first section and part of the second section forming a first portion and part of the second i section and the third section forming a second portion, the first portion abutting the second portion, the first portion including a warmer and a heating device, the warmer and the heating device positioned within generally about six feet of each other so as to be within an arm span of a worker, the second portion including an accompaniments container proximate the heating device and a packaging dispenser, the accompaniments container and the packaging dispenser positioned within generally about six feet of each other so as to be within an arm span of a worker.

In another aspect, there is provided a food product assembly area comprising a first station and a second station, the first station generally located at a juncture between a first counter section and a second counter section and the second station generally located at a juncture between the second counter section and a third counter section, the first counter section, the second counter section and the third counter section arranged in a generally U-shaped configuration, a first storage compartment for a food product base disposed on at least one of the first and second counter sections within arm's reach from the first station, a P:\OPER\DH\63282-98 rs2.doc-25/0&01 -3heating device for a food product component to be applied to the food product base disposed on at least one of the first and second counter sections within arm's reach from the first station, a second storage compartment for a chilled food product component to be applied to at least the food product base disposed on at least one of the second and third counter sections within arm's reach from the second station, and a packaging dispenser disposed on at least one of the second and third counter sections within arm's reach from the second station, the first station and the second station being arranged so as to enable a first worker positioned at the first station to directly pass the food product to a second worker 10 positioned at the second station.

Further aspects of the present invention will be apparent in view of the disclosure below.

Brief Description of the Drawings These and other features of the invention will now be described with reference to the drawings of two preferred embodiments which are intended to illustrate and not to limit the invention, and in which: 15 Figure 1 is a top plan view of a food preparation line that is configured in accordance with a first preferred embodiment of the present invention; Figure 2 is a front elevational view of a first section of the preparation line as viewed in the direction of lines A-A of Figure 1; Figure 3 is front elevational view of a second section of the preparation line as viewed in the direction of 20 lines B-B of Figure 1; Figure 4 is a front elevational view of third section of the preparation line as viewed in the direction of lines C-C of Figure 1; Figure 5 is a front elevational view of a corner section of the preparation line as viewed in the direction of lines D-0 of Figure 1; 25 Figure 6A is a sectional side view of a steam cabinet configured in accordance with a preferred embodiment of the present invention; Figure 6B is an enlarged sectional view of the area within circle BB of Figure 6A and illustrates a door drip edge; Figure 7 is a rear elevational view of the steam cabinet of Figure 6A; Figure 8 is a perspective view a shelf of a hanging storage system that is shown in Figure 1 and is configured in accordance with a preferred embodiment of the present invention; Figure 9 is an enlarged perspective view of the area within Circle 9 of Figure 8 and illustrates a hook of the storage shelf; Figure 10 is a perspective view of a container holder of the hanging storage system of Figure 1; Figure 11 is a side elevational view of the container holder of Figure Figure 12 is a perspective view of a wrap holder of the hanging storage system of Figure 1; -3: WO 98/36668 PCT/US98/02997 Figure 13 is a side elevational view of an ingredient dispenser of the food preparation line of Figure 1; Figure 14A is an enlarged, partial sectional, side view of a pump and valve assembly of the ingredient dispenser of Figure 13, and illustrates the pump in a metering stoke of the dispensing cycle; Figure 148 illustrates the pump and valve assembly with the pump in a delivery stroke of the dispensing cycle; and Figure 15 illustrates a top plan view of a food preparation line that is configured in accordance with another preferred embodiment.

Detailed Description of the Preferred Embodiment Figure 1 illustrates a food preparation line 1 that is configured in accordance with a first embodiment of the present invention. The preparation line 1 is designed to improve the speed of service shorten individual food preparation time) while reducing the number of employees on the preparation line, as well as to improve the consistency of ingredient portions between like products. In particular, the food preparation line of the present invention advantageously allows two workers to efficiently perform the work of at least three workers in a quickservice restaurant environment. The preparation line 1 is also preferably self monitoring to indicate the malfunction of any of the various components of the line. In addition, the preparation line measures the duration of time that ingredients remain on the line for health concerns. The preparation line 1 thus has particular utility in "quick-service" restaurants. The preparation line 1 is accordingly illustrated and described in connection with a quick-service, mexican-entree restaurant, such as, for example, a Taco Bell® restaurant. It shall be understood, however, that the skilled artisan can readily adapt the preparation line 1 to be used in other types of food preparation facilities or restaurants.

Figure 1 best illustrates a desired shape of the food preparation line 1. For this purpose, the preparation line 1 includes a first section 3, a second section 5, and a third section 7 that are arranged to form a shape. The second section 5 extends between corresponding ends of the first and third sections 3, 7, while the first and third sections 3, 7 extend generally parallel to each other. Each section 3, 7 terminates at an outer end 2, 52. The modular nature of the line 1 created by the separate sections 3, 5, 7, however, allows the line to be arranged in other configurations. The line 1 need not be formed in a perfect U-shape with the first and third sections 3, 7 parallel to each other and the second section 5 perpendicular to the other sections 3, 7, as will be described below.

A heated storage compartment is provided along the first section of the preparation line. The heated storage compartment can be any of a number of devices designed to maintain food products at an elevated temperature. In the illustrated embodiments, the heated storage compartment can be either the steam cabinet 100 or the heating cabinet 14. One skilled in the art will appreciate that the heated storage compartment can also comprise a bun warmer, hot plate or other similar devices.

A heating device is also provided along the preparation line. The heating device of the illustrated embodiments is a steam table 20. The heating device can either maintain food at an elevated temperature or cook WO 98/36668 PCT/US98/02997 -6" food, items being prepared along the food preparation line. One skilled in the art will readily recognize that the heating device can be an oven, a grill, a range top, a hot plate or other similar devices.

A cooled storage compartment is provided along the second section of the preparation line. The cooled storage compartment can be any of a number of devices designed to maintain food products at a temperature below room temperature. In the illustrated embodiments, the cooled storage compartment can be either the open produce bin 32 or the refrigerators 38. One skilled in the art will appreciate that the cooled storage compartment can also comprise a cool rail, ice chest or other similar devices.

As is common to each section, a counter top 17, 34, 47 extends along the length of the first, second and third sections 3, 5, 7, respectively, at about waist height 2/ to 4 feet high). Along the edges of the counter tops 17, 34, 47, as well as along the edges of the shelves and cabinets, a plurality of mounting studs 19 (Figure 2) can be placed. The mounting studs 19 desirably are spaced apart at eight inch intervals, center to center, and are shaped to cooperate with key holes formed in a variety of movable line components, such as, for example, removable shelving, dispensers and storage devices.

Along this line, the line 1 can include one or more removable shelves attached to a side edge of one of the counter tops. For instance, in the illustrated embodiment, a removable angled shelf 42 is positioned at the corner 11 between the second and third sections 5, 7. The angled shelf 42 is positioned at the surface level of the preparation line 1, even with the counter tops 34, 47, so that food items can be set upon the shelf before they are packaged. The angled shelf 42 includes a plurality of key holes formed along side edges of the shelf which cooperate with the mounting studs 19 to releasably attach the shelf 42 to the second and third sections 5, 7.

A second removable angled shelf 43 desirably is located at the corner 9 between the first and second sections 3, 5. The angled shelf 43 is positioned at the surface level and is releasably attached to the sections 3, using the mounting studs 19.

As illustrated in Figures 1 and 2, the first section 3 includes a steam cabinet 100 near the outer end 2 of the section 3. Because the preparation of many food items initially begin with tortillas, the steam cabinet is arranged at the starting point of the preparation line 1. As Figures 1 and 2 illustrate, the steam cabinet 100 desirably lies on a shelf above of the counter top 17 of the first section 3.

The steam cabinet 100, which will be described in detail below, has a semi-enclosed steam chamber. In the exemplary application, the steam cabinet 100 stores flour tortillas and keeps them warm pending use during food product preparation. For this purpose, the steam cabinet produces 90-100% humidity within the steam chamber and maintains a temperature ranging between 120.1400 F within the chamber.

The steam chamber desirably has a sufficient size so as not to require restocking during extended periods of use. For example, the quantity of supply should be sufficient to not require any additional stocking during a threehour lunch period in the middle of the afternoon. For this purpose, the steam chamber advantageously includes four shelves which are sized to hold 192 tortillas of 10.5 inch diameter and 288 tortillas of 6.5 inch diameters.

WO 98/36668 PCT/US98/02997 .o7.

The steam cabinet 100 has an open face which opens directly into the steam chamber. An air curtain keeps the steam within the chamber, as described below. The open face eliminates the need to constantly open and close a front door when getting a tortilla.

The steam cabinet 100 also includes a rear door that opens directly into the steam chamber. The rear access to the steam chamber allows tortillas to be loaded into the steam cabinet 100 without interfering with the operation of the worker on the preparation line 1.

Directly below the steam cabinet 100 is wrap storage station 12. From this location, a worker places a tortilla from the steam cabinet 100 directly on a wrap paper andlor foil sheets).

The wrap storage station 12 includes a plurality of tiered compartments that are sized to hold wraps in a flat manner. This layout makes the wraps easier to discern from one another, easier to access and easier to grab.

Finger holes are also provided to further assist with the latter advantage. The storage station desirably includes at least six compartments which are adequately sized to hold a sufficient amounts of wraps to last through a three.hour rush period a daily lunch period).

The storage station 12 sits atop the counter top 17 with the steam cabinet 100 sitting on the storage station 12. The counter top 17 in front of the station 12 can be used to prepare food items. For example, flour tortillas removed from the steam cabinet 100 can begin their preparation on the counter top 17.

A heated cabinet 14 is located on the line's first section at a position directly below the wrap storage station 12. The heated cabinet 14 is configured to maintain a predetermined quantity of ingredients before the ingredients are placed on the line. The quantity of ingredients desirably is sufficient to not require restocking during extended periods of use. For example, the quantity of supply can be sufficient to not require any additional stocking during a three-hour lunch period in the middle of the afternoon.

In the illustrated embodiment, a half height heating cabinet 14 is used. The cabinet 14 desirably includes a front door and a rear door to allow loading from the rear so as not to the disturb the line workers. A suitable heating cabinet 14 is commercially available from BevIes, of Chino, California.

Located adjacent to the steam cabinet 100 is a bean cup dispenser 16. In the illustrated embodiment, the bean cup dispenser 16 is attached to the steam cabinet with key hole slots to allow the dispenser 16 to be movable.

The bean cup dispenser 16 is an enclosed sanitary chamber configured to receive a predetermined quantity of cups.

Any of a variety of conventional cup dispensers can be used for this purpose. A suitable cup dispenser is available from Antunes, of Addison, Illinois. It also will be understood that the bean cup dispenser 16 can store cups for products other than pinto beans. For example, extra red sauce, nacho cheese, meat, or other food items can be placed in the cups. Accordingly, the line 1 can include more than one cup dispenser positioned at or near this location.

The cup dispenser 16 desirably includes a plurality of mounting studs 19 that extend vertically along the dispenser 16. As best seen in Figure 2, one or more paper wrap dispensers 45 soft taco wrap dispensers) are removably attached to the side of the dispenser 16 for easy access by the line worker.

WO 98/36668 PCTIUS98/02997 -8- Below the bean cup dispenser 16 is a section of the generally flat working counter top 17. This space also can be used as a food preparation surface.

A water filtration system 18 is located below the bean cup dispenser 16 and the counter top 17. The filtration system filters and regulates the water used in a steam well 20 on the line.

A steam table lies at the corner 9 formed between the first and second sections of the line 1 in the illustrated embodiments. As best seen in Figure 5, the steam table 20 is positioned at the surface level of the counter top 17 which allows food to be served quickly and smoothly. The steam table 20 maintains a hightemperature water bath heated by heating elements. In the illustrated embodiment, the steam table 20 includes three full size compartments. Each compartment is heated by a 20 amp heating element. Though the line is described as including a steam table, it is understood that a drop-in dry hot well system can be used as well. Additionally, as will be appreciated by those skilled in the art, the steam table may also be replaced by a grill or other cooking surface.

Pans holding an assortment of food ingredients are placed in the steam table 20. It will be understood that the steam table 20 can accommodate pans of various sizes. For example, three one-third pans can fit within each compartment of the steam table 20, as will 18 one-sixth pans and 27 one-ninth pans. The pans contain ingredients that need to be kept at a warm temperature. For example, additional meat, beans and red sauce are stored in pans in the steam table 20. In addition to these ingredients, green sauce, nacho cheese and chili, as well as other ingredients, are stored in pans within the steam table Figures 1 and 3 illustrate a steam well digital control panel 28 positioned on the second section 5 adjacent to the corner 9 and the steam well 20. In applications having a steam table, the water level in the steam table is controlled by the digital control system 28, which is located on the second section 5 below the surface level 34, as seen in Figure 3. The digital control system 28, through the use of probes in the steam table, operates the water fill system 18 (Figure which, in turn, adds water to the steam table 20. A manual drain is used to drain water from the steam wells when cleaning the line. Should the water lvel drop below a certain level and remain below after the fill operation (as would be the case if a line worker left the manual drain open), the digital control system 28 will alert the line worker of this abnormal condition and will turn off the heating elements if the problem persisted.

The digital control system 28 also monitors the conditions of the heating elements in the steam table to ensure they are operating properly. The digital controls 28 found to be suitable for controlling the steam table 20 of the present invention are commercially available from Digital Knights of Aliso Viejo, California.

Above the digital controls 28 are indicators 26. It will be understood that the indicators 26 can be lights, audio alarms (either verbal or non-verbal), or visual displays. The indicators 26 indicate diagnostic changes in the water level and water temperature in the steam table As shown in Figure 2, above the order display 22 is a timer 21 that, for food health reasons, monitors the length of time that food ingredients have been exposed or open to the atmosphere. The timer 21 preferably has twenty-one channels, each assigned to a different ingredient. The timer 21 can monitor the time in which up to WO 98/36668 PCT/US98/02997 .9.

twenty-one ingredients have been in their respective environments. The timer 21 counts down from a maximum period of time in which each ingredient can safely remain in its particular environment. The preferred timer 21 counts down from this predetermined time towards zero. When the timer 21 counts down to zero for a particular ingredient, the timer 21 will indicate that the exposure time for the ingredient has lapsed, and a line worker will replace the ingredient with a fresh supply of the ingredient.

With reference to Figures 1 and 5, an ingredient dispenser 120, which will be described in fuller detail below, is located behind the steam table in the corner 9 between the first and second sections 3, 5. The ingredient dispenser 120 includes nozzles 126 that are arranged above the steam table 20 for easy access. The ingredient dispenser precisely pumps predetermined amounts of ingredient when activated, as well as dispenses ingredients more quickly than can be accomplished by hand.

For this purpose, the ingredient dispensing unit 120 includes a positive displacement pump to dispense food ingredient in precise, predetermined portions. The ingredient dispenser 120 can be used to dispense a number of different ingredients. For example, refried beans, ground beef and red sauce can be dispensed through the ingredient dispensing unit 120. Each food ingredient would require its own separate ingredient dispenser.

As illustrated in Figures 1 and 5, in corner 9, defined by the joining of the first section 3 and the second section 5, is a heated shelf 24. The heated shelf 24 is heated by one or more lamps and is positioned above the ingredient dispensing unit 120 at approximately eye level and is designed to store a predetermined quantity of ingredient. The quantity of ingredient advantageously is sufficient to not require restocking during extended periods of use. For example, the quantity of supply desirably is sufficient so as not to require any additional stocking during a three-hour lunch period in the middle of the afternoon. In the exemplary application, the heated shelf 24 desirably stores ingredients such as taco shells, tostada shells, nachos and other food items that need to be kept crisp. The ingredients are, thus, kept at a predetermined, warm temperature.

As best seen in Figures 2 and 5, the order display 22 is positioned above the steam table, on the back facing, below the heated shelf 24. The line worker can easily read the orders to coordinate product preparation from the display. The display 22 desirably is a flat screen, such as the type available commercially from Datalux, of Winchester, Virginia, in order to save space on the line.

As illustrated in Figure 3, an auxiliary ingredient dispenser 27 is positioned above the digital control panel 28. The ingredient dispenser 27 permits line workers to dispense ingredientssuch as, for example, but without limitation, sour cream, guacamole andlor beef, in accurate portions. Moreover, the easy accessibility of the ingredient dispenser 27 increases the speed in which food items can be prepared. An ingredient dispenser found to be suitable in the food preparation line 1 is a dispenser commercially available from Frymaster of Shreveport, Louisiana.

A wrap storage station desirably is positioned between the auxiliary ingredient dispenser 27 and the control panel 28. The storage station is convenient located in proximity to the heated shelf 42, ingredient dispensers 120, 27 and the steam table On the second section 5, adjacent to the auxiliary ingredient dispenser 27, is a cheese melter 32. The cheese melter 32 is located on a shelf 51 that extends above the counter top 34. The cheese melter 32 desirably WO 98/36668 PCTIUS98/02997 uses hot steam heat to melt cheese on some products. For this purpose, a source of filtered water is connected to the cheese melter 32.

A quesadilla warmer 53 is located on the counter 47 of the third section 7. The quesadilla warmer 53 preferably has two independent lids. The quesadilla warmer 53 has a pair of lids whereby one lid to the quesadilla warmer 53 can remain closed while the other lid is opened to insert or remove product from the warmer 53. This configuration permits a line worker to place a quesadilla into the quesadilla warmer 53 via one lid while another quesadilla is already inside the quesadilla warmer 53. Line workers thus can cook a second quesadilla without waiting for the first cycle to complete. That is, the split lid allows the quesadilla warmer 53 to function essentially as two quesadilla warmers 53 in the space of one. A warmer found to be suitable as a quesadilla warmer 53, without the split lid improvement, is a warmer manufactured by Star Manufacturing of St. Louis, Missouri.

As illustrated in Figures 1 and 3, a produce bin 36 is located on the second section 5, below the cheese warmer 33. The produce bin 36 receives and store predetermined amounts of produce. The quantity of produce stored within the bin 36 and an on-line refrigerator 38 desirably is sufficient so as not to require restocking during extended periods of use. For example, the quantity of supply can be sufficient to go without resupply for a threehour period in the middle of the afternoon. In the preferred embodiment, the produce bin 36 holds a variety of produce to be added to food ingredients as they proceed along the preparation line 1 from the ingredient dispenser 120 or steam table 20. For example, accompaniments such as lettuce, tomatoes, olives as well as cheese and sour cream are added to the food items that proceed to the second section 5 of the preparation line 1. The produce bin 36 can hold five one-third pans and five one-sixth pans which, in turn, store the produce. The produce bin may be located proximate a Bloomington Rail, manufactured by the Delfield Co. of Mount Pleasant, Michigan.

As shown in Figures 1 and 3, above the produce bin 36 is a wrap storage system 150. The wrap storage system 150, which will be described in fuller detail below, is configured to receive predetermined quantities of product packaging. The wrap storage system 150 hooks on to the preparation line 1 and stores containers which, in turn, hold product packaging used to wrap the final product before delivery to the customer. The modular nature of the wrap storage system 150 allows it to be hung anywhere along the food preparation line 1. Such optimal positioning advantageously permits easy accessibility to product packaging.

Positioned in front of the produce bin 36 in Figure 3 is a taco rail 40. The taco rail 40 sits on the counter top 34 and is configured to receive tacos and maintain them in an upright position. The taco rail 40 positions tacos that have already been loaded with meat andlor beans in an upright position to permit the worker to load produce on the taco without the taco tipping and spilling produce. Accordingly, as shown in Figure 3, the taco rail extends between the steam table and the third section of the preparation line.

Below and proximate the counter top 34 and taco rail 40 is a waste container 30. Adjacent to the waste container 30 and below the produce bin 36 is another waste container 31. Produce that has fallen from food items during food preparation and settled on the counter top 34 or taco rail 40 can be easily swept into the waste containers 30, 31 to ensure that the preparation line 1 remains sanitary. Waste containers 30, 31 found to be suitable for use with the present invention are commercially available from Rubbermaid of Winchester, Virginia.

WO 98/36668 PCT/US98/02997 -11- Below the waste container 31 are dual refrigerators 38 to store cold items. The dual refrigerators are located, generally, at the floor level. Using two refrigerators 38 at this position increases storage capacity. For example the dual refrigerators 38 hold six full pans (or eighteen one-third pans), a quantity sufficient to fully supply the food preparation line 1 during a three hour peak period.

Figure 4 illustrates a monitor 50 proximate to the corner 11, formed by second section 5 and the third section 7. The monitor 50 is positioned on a shelf 41 that extends at approximately eye level along the third section 7. The monitor 50 indicates orders taken from the drive-through window. As the food items continue down the preparation line 1 from the ingredient dispenser 120 to the produce bin 36, line workers can reference the monitor to determine what orders need to be prepared for the drive-through window. As the drive-through orders are prepared, they are handed through the pass-through area 49 to employees working the drive-through window.

On the third section 7, adjacent to the order display 50, is the wrap storage system 150. The wrap storage system 150, which will be described in fuller detail below, is configured to receive predetermined quantities of product packaging. The wrap storage system 150 holds product packaging corresponding to different food items.

The wrap storage system 150 provides easy access to the packaging to further expedite food preparation. In addition, the wrap storage system 150 is modular so as to be removably mounted anywhere along the preparation line 1.

A bag opener 48 can be located adjacent to the wrap storage system 150, on the third section 7. As one bag is removed, the next is automatically opened. With the bag partially open, the worker is able to load the packaged items into the bag more quickly. This may enhance product flow through the entire preparation line 1.

The bag opener 48 also has an increased bag capacity holding 130 #4 and 110 #6 bags. This supply is sufficient to eliminate any need to restock the bag opening 48 during a three hour lunch peak.

At the end of the preparation line 1, on the third section 7, is a tray dispenser 46. The tray dispenser 46 stores stacked trays within the lower level cabinet and dispenses the trays through an aperture in the counter top 47. By placing the trays in the cabinet, a sufficient supply of trays can be stacked in the dispenser 46 to eliminate the need to frequently stock the dispenser 46. The packaged food items, if not placed in the bags for a carry-out order, are placed on the trays to be delivered to the customer. The illustrated embodiment utilizes a tray lowerator.

A hand sink 45 and sanitizer 45a are positioned at the end of the third section 7 near the tray dispenser 46. The hand sink 45 has running water and a drain positioned on the bottom interior surface of the sink 45. Line workers entering the food preparation line 1 use the sink 45 to wash their hands in order to maintain sanitary conditions on the food preparation line 1. Similarly, when line workers exit the food preparation line, they can wash their hands in the sink 45. Moreover, as line workers prepare products on the food preparation line 1, any ingredients that come in contact with the line workers' hands can be quickly washed away. The sink 45 permits the line workers to conveniently and quickly wash their hands in order to maintain a sanitary food preparation line 1.

The sanitizer 45a is preferably located adjacent to the sink 45 as illustrated in Figure 1. The sanitizer is provided with a drain and desirably cannot be filled using the faucet associated with the sink. In use, the sanitizer WO 98/36668 PCTIUS98/02997 -12holds a cleaning solution and towels. The cleaning solution can be either poured directly from a bottle or diluted using water transferred from the sink. No faucet is provided in the sanitizer to eliminate the possibility of accidental dilution of the cleaning solution.

Positioned in the corner 11 formed by the second section 5 and the third section 7, is a cash register (not shown). The cash register faces away from the line workers on the food preparation line 1 and towards the drivethrough window. The register is accessible through the pass-through area 49 to employees working the drive-through window. The position of the register desirably permits employees working the drive-through window to conveniently enter orders and pick-up prepared products in the same location.

In the corner 11, underneath the surface level, is a refrigerator 38 (Figure The refrigerator 38 can be accessed from the rear of the preparation line 1. The rear access refrigerator 38 is accessible to workers stationed at the drive-through window. The drive-through workers, thus, do not have to walk around the preparation line 1 to the refrigerator 38 to obtain milk, juice and other refrigerated items. Rather, these items can be stored in the rear access refrigerator 38 and accessed from behind the third section 7.

The above described preparation line 1 desirably is sized and arranged to allow just a few workers to handle the line. In the illustrated embodiment, the line 1 can be formed to have a foot-print of approximately 12 feet by six feet and be configured to allow two line workers to efficiently prepare ordered meals. The arm-span of the workers, positioned at the two inside corners of the preparation line, can cover the entire preparation line. Thus, advantageously, two workers can remain relatively stationary and complete each of the tasks along the food preparation line. Labor costs of course are reduced with the use of less workers on the line. The increased capacity of on-line storage within the produce refrigerator, heating cabinet and packaging storage stations, also eliminates the need to restock the line during times of peak production, such as, for example, during a three-hour lunch rush.

As a result, a full time stock or prep person does not have to be employed, thereby furtherreducing labor costs.

In addition to reducing labor costs, the arrangement of the line 1 also improves the flow of meal preparation. That is, preparation proceeds in a more orderly fashion along the line. The speed of service in the restaurant advantageously increases.

The modular nature of several of the components of the line also readily accommodates changes to the restaurant's product menu. Special ingredients and packaging for new products are easily integrated into the overall arrangement of the preparation line.

The following will now elaborate upon the steam cabinet 100, the hanging storage system 150 and the ingredient dispensing system 120 of the food preparation line 1 described above.

Figure 6A illustrates a steam cabinet 100. A steam chamber 114 is generally defined by the walls of the steam cabinet 100. A fan unit 102 is desirably positioned outside the steam flow within the steam chamber 114.

Adjacent to the fan unit 102 is a heating element 104. A laminar air flow passage 106 extends within and along the bottom of the steam cabinet 100. The air flow passage 106 further extends partially along the side the steam cabinet 100. An air curtain 110 defines a side of the steam chamber 114. Above and adjoining the air curtain 110 WO 98/36668 PCT/US98/02997 -13.

is a swinging door 112 that extends partially down along the open side of the steam cabinet 100. An exhaust system 116 is positioned at the top of the steam chamber 114. The exhaust system 116 includes a manual vane 111 (Figure Directly below the exhaust system 116, and positioned at the top of the steam chamber 114, is a heating element 118. Within the steam chamber 114 is a shelving unit 113. The rear panel 115 of the steam chamber 114 is a door. As best illustrated by Figure 7, a latching mechanism 119 is mounted to the rear access door 115.

Flour tortillas or other food ingredients are placed within the steam chamber 114 on the shelving unit 113 to be heated. The cabinet is configured to maintain a predetermined quantity of tortillas. The quantity of tortillas desirably is sufficient to not require restocking during extended periods of use. For example, the quantity of supply can be sufficient to not require any additional stocking during a three-hour lunch period in the middle of the afternoon.

A steam well 108 is positioned at the bottom of the steam chamber 114, and within the steam well 108 are heating elements 117. A water bath is maintained in the steam well 108.

Figures 6A.7 illustrate a rear access door 115 comprising the back panel of the steam cabinet 100 and providing access to steam chamber 114. A latch unit 119 is mounted on the rear access door 115 and steam cabinet 100. A drip edge channel 101 is provided below the door as illustrated in Figure 6B. The drip edge 101 and sloping surface channels away any condensation which may accumulate on the inner surface of the door.

Specifically, as shown in Figure 6B, any condensation which may form on the inside of door 115 will be pulled downward by gravity. The condensation will fall from the bottom of the door into the channel 101. Any condensation remaining on the bottom of the door 115 will be swept into the channel by the edge 101a. Thus, the drip edge channel 101 traps condensation which forms of the inside and bottom surfaces of door 115. The channel can be configured to drain the condensation back into the steam well 108. As will be appreciated by those skilled in the art, the channel may also be drained to a location outside of the steam cabinet.

As illustrated by Figure 6A, the heating element 104 heats the air within the air flow passageway 106.

The fan unit 102 forces the heated air through the air flow passageway 106. The heated air extends across the open side of the steam chamber 114 to the swinging door 112 thereby creating a laminar air curtain 110. The laminar air curtain 110 acts as a seal to prevent steam and heat from escaping into the atmosphere from the steam chamber 114.

As mentioned above, a water bath is maintained in the steam well 108. The water is heated to a predetermined temperature by the heating elements 117 thereby creating steam. The steam rises into the steam chamber 114 and permeates the inside of the steam chamber 114. Food ingredients placed on the shelving unit 113 within the steam chamber 114 are kept warm by the rising steam and the heat radiated by the upper element 117.

As the steam continues to rise within the steam chamber 114, it reaches the top of the steam chamber 114 where it comes into contact with the heating element 118. The heating element 118 emits heat of a predetermined temperature sufficient to cause the steam to dissipate thereby preventing moisture from accumulating on the top surface within the steam chamber 114 and raining down on the food ingredients positioned on the shelving unit 113.

WO 98/36668 PCT/US98/02997 -14- The exhaust system 116 expels steam from the steam chamber 114 to permit newly formed steam to circulate within the steam chamber 114. The manual vane 111 included in the exhaust system 116 is manually adjustable to create a gap at the top of the steam chamber 114. The gap, which can be widened or closed, permits steam and heat within the chamber to escape into the atmosphere. The gap is manually adjusted to create a gap of a certain width to allow steam and heat to be expelled from the steam chamber 114, while maintaining a temperature within the steam chamber 114 that is sufficient to keep the ingredients warm.

The laminar air curtain 110 permits an individual to reach into the steam chamber 114 to withdraw food ingredients without the having to open a door. The swinging door 112 decreases the distance which the heated air flow must span to create an effective air curtain 110. An access door 115, located in the rear of the steam cabinet 100, permits an individual to load food ingredients into the steam chamber 114 to be prepared, while not interfering with an individual withdrawing food ingredients through the air curtain 110.

Figures 8-12 illustrate a wrap packaging storage system 150. The system involves a wrap storage shelf 152 configured to receive a container 158, 162. A securing slot 156 extends along substantially the full length of the bottom surface 153 of the wrap storage shelf 152. The bottom surface 153 is desirably indented along substantially its entire length to form the slot 156. The side panels 155 of the wrap storage shelf 152 are configured with an attachment means 154 for hanging the wrap storage shelf from at least one rod 157. For example, the hooks 154 defined by or attached to the side panels 155 of the wrap storage shelf 152 would be suitable attachment means. The hooks 154 define an aperture 159 and are configured to receive a rod 157.

As mentioned above, it will be understood that the wrap storage shelf system 150 is modular in nature and may be positioned at any point along the preparation line 1 where a rod 157 is mounted. The wrap storage shelves 152 can be produced in any number of sizes as well to fit within the preparation line 1 where necessary.

Moreover, shelves 152 can accommodate wrap containers 162, 158 of varying shapes and sizes to accommodate different packaging corresponding to different products.

The wrap storage shelves 152 are configured to receive containers 162, 158. As shown in Figures 10 and 11, the container 162 is defined by two side panels 165,169, a rear panel 167, a front panel 163 and a bottom panel 171. An aperture 168 is configured on the front pinel 163. Flanges 164, 166 are mounted on the bottom surface 171 of the container 162. Flange 164 is angled forward to a sufficient degree to permit it to interlock with the slot 156 of the wrap storage shelves 152. Flange 164 may alternatively be angled backward. Flange 166 will extend approximately perpendicular to the bottom surface 171 of the container 162. A hole 170 is defined by the perpendicular flange 166, the front panel 163 and side panels 165,169.

As best illustrated by Figure 12, a wrap container 158 is fitted with a flange 160 which depends approximately perpendicular from the bottom surface 175 of the wrap container 158. The bottom surface 175 further defines a lower shelf of the wrap container 158. A second shelf is defined by an intermediate panel 177 positioned between side panels 178,179 and parallel to the bottom panel 175.

The wrap storage shelf 152 hangs from the rod 157 through the hook 154. The rod 157 is mounted along needed points on the preparation line 1. Placed at predetermined points along the rod 157 are supports. The WO 98/36668 PCT/US98/02997 supports are mounted to the food preparation line 1 and are connected to the rod 157. The supports are spaced at a distance that is sufficient to prevent the rod 157 from bowing under the load of the shelf 152 and containers 162, 158.

Wrap containers 162 and 158 are placed in the wrap storage shelf 152. The angled flange 164 underneath the bottom surface 171 of the container 162 will slide into the slot 156 on the inside bottom surface 153 of the wrap storage shelf 152. This will prevent the container 162 from sliding off the shelf 152 when a carton is removed from the container 162. The product packaging is removed from the wrap container 162 through the hole 170. Advantageously, an individual can secure the product packaging at aperture 168 and pull the packaging out through the hole 170.

The perpendicular flange 166 will prevent the wrap container 162 from being pushed backwards thereby displacing the angled flange 164 on the container 162 from the slot 156 on the wrap storage shelf 152. To remove the container 162 from the wrap storage shelf 152, the container 162 is lifted from the thumb hole 168 in a vertical direction to a height sufficient for the perpendicular flange 166 to clear the front edge 151 of the wrap storage shelf 152. Then the wrap container 162 is pushed backwards so that the angled flange 164 can clear the slot 156 at which time the entire wrap container 162 can be lifted out of the wrap storage shelf 152.

The wrap container 158 does not have an angled flange fitting into the slot 156 of the wrap storage shelf 152. Instead, the wrap container 158 is positioned within the wrap storage shelf 152. The wrap container 158 stores product packaging on shelves 175, 177, and the product packaging is pulled from the top of a pile of packaging on each shelf 175, 177.

As illustrated in Figures 13.14B, the ingredient dispenser 120 is positioned in the corner 9 of the product line 1. The ingredient dispenser 120 is positioned within a cabinet 121 out of plain view. The cabinet 121 includes a heated compartment in which the hoppers 124 of the system 120 are located. Access to the hoppers 124 is gained through a rear access door located on the rear side of the first line section 3. A controller 33 (Figure 3) communicates with internal sensors within the heated compartment and regulates the corresponding heating elements to control the temperature of the ingredients within the hoppers 124.

A mixing motor 123, positioned within the cabinet 121 and above the hopper 124, operates a mixer 122.

The mixer 122 extends into the ingredient (not shown) within the hopper 124. The hopper 124 is in communication with a two-position valve 130. In the first position, as illustrated in Figure 14a, the valve 130 is connected to the piston chamber 144. In the second position, as illustrated in Figure 14b, the valve 130 is in communication with an outlet port 136. The outlet port 136, in turn, is in communication with an outlet tube 125. Dispensing nozzles 126 are configured at the end of the outlet tube 125. Desirably, each tube 125 is wrapped with a conventional heating blanket (not shown), such as those commercially available from Watlow of St. Louis, Missouri, to maintain the ingredient within the tube 125 at a desired temperature. A controller 33 (Figure 3) operates the heating blankets. The dispensing nozzles 126 hang down from an overhead cabinet 128.

WO 98/36668 PCT/US98/02997 -16- A positive displacement pump assembly 140 and valve 130 found to be suitable as components of the ingredient dispenser 120 of the present invention is a pump and valve assembly manufactured and distributed by Itoh Kouki of Japan.

Figure 14A illustrates a two-position valve 130 in communication with a piston pump assembly 140. An inlet port 134 is interposed between the hopper 124 and the two-position valve 130. An outlet port 136 is interposed between the two-position valve 130 and the outlet tube 125. The valve member 132 of the valve 130 is in an intake position. A piston chamber 144 extends outward from the valve 130. Within the piston chamber 144, a piston 142 is withdrawn from the piston chamber 144.

As illustrated in Figure 14B, the valve member 132 is in an outlet position. Further, the piston 142 is fully inserted within the piston chamber 144.

The hopper 124, which holds a predetermined amount of ingredient 127, is loaded from the top when it becomes low. The quantity of ingredient 127 in each hopper 124 desirably is sufficient to not require restocking during extended periods of use. For example, the quantity of supply can be sufficient to not require any additional stocking during a three-hour lunch period in the middle of the afternoon.

As illustrated in Figures 13 and 14A, to operate the ingredient dispenser 120, compressed air drives an actuator 129 which, in turn, drives the piston 142. A conventional compressor supplies the compressed air to the air cylinders.

To dispense ingredient, the piston 142 is fully withdrawn from the piston chamber 144. This pulls ingredient 127 from the hopper 124, through the inlet port 134 and into the valve chamber 133 and piston chamber 144. The back-pull of the piston 142 withdraws a precise, predetermined amount of ingredient 127 into the valve chamber 133 and piston chamber 144. In doing so, the valve member 132, within the valve chamber 133, is rotated by a seqond actuator 138 (Figure 13) in a counter-clockwise direction to the position illustrated in Figure 14B. As illustrated in Figures 13 and 14B, the air cylinder 129 then drives the piston 142 forward within the piston chamber 144. This, in turn, forces the ingredient 127 through the piston chamber 144, into the valve chamber 133, and out through outlet port 136. Because a quantity of ingredient 127 is perpetually present in the outlet tube 125, the same proportion of ingredient withdrawn from the hopper 124 by the piston 142 and driven through the outlet port 136 will expel through nozzle 126.

The counterclockwise rotation of the valve member 132 from the position illustrated in Figure 14A to the position illustrated in 14B, effectively blocks the inlet port 134 and then the piston 142 forces the ingredient 127 through outlet port 136. This operation will repeatedly dispense approximately the same proportion of the ingredient 127.

The ingredient dispenser 120 also includes a red sauce dispensing mechanism in which a submergible pump is located within a container of red sauce. The container is positioned within the heated compartment within the cabinet 121. A delivery line extends from the pump to a discharge nozzle located adjacent the dispenser nozzle 126.

Figure 15 illustrates another embodiment of a food preparation line. The embodiment of Figure 15 in generally configured in accordance with the embodiment of Figure 1. The third section in the embodiment of Figure P:\OPER\DH 63282-98 rsI.do-27103/01 17however, desirably is angled relative to the first section. The angle is preferably about 450 but may vary over a broad range as can be appreciated by those skilled in the art. Importantly, the distance between the open produce bin 32 and the packaging containers 150 is less than about six feet. The distance is desirably determined by the average arm span of a worker. Additionally, the distance between the heated storage container and the steam table is similarly determined by the average arm span of a worker and is less than about six feet.

Although the foregoing invention has been described in terms of an illustrated embodiment, other embodiments will become apparent to those of ordinary skill in the art, in view of the disclosure herein. Accordingly, the present invention is not intended to be limited by the recitation of illustrated embodiment.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

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Claims (29)

1. A food preparation line comprising a first section, a second section lying generally normal to the first section, and a third section positioned next to and extending away from the second section at an angle and in the same general direction as the first section, a first inside corner being defined at a juncture between the first section and the second section, a second inside corner being defined at a juncture of the second section and the third section, a heated storage compartment positioned on the first section, a cooled storage compartment 1 positioned on the second section, a heating device being positioned on the first inside corner and a generally open package storage compartment located near an end of the third section, which end is distal of the second section, whereby the *:.*packaging stored in the generally open package storage compartment are easily accessed.

2. The food preparation line of Claim 1 additionally comprising a pass-through eoeoe 15 area arranged on the third section.

3. The food preparation line of Claim 1, wherein the heated storage compartment has an access opening on two sides.

4. The food preparation line of Claim 1, wherein the first, second and third sections are arranged generally in a U-shape with the first and third sections being positioned generally parallel to each other.

The food preparation line of Claim 1, wherein the heating device comprises a hot ingredient well positioned at a working level of the line.

6. The food preparation line of Claim 1, wherein the cooled storage compartment comprises an open produce bin.

7. The food preparation line of Claim 6, additionally comprising a taco rail positioned on the second section and extending along at least a portion of a length of the produce bin. P:\O)PER\DH63282-98 rs2.doc-25/060 1 -19-

8. The food preparation line of Claim 1, wherein said heated storage compartment comprises a steam cabinet that is arranged on the first section, said steam cabinet comprising a housing having a substantially vertical opening and at least partially defining a steam chamber, the opening extending into the steam chamber and providing substantially unfettered access into the steam chamber.

9. The food preparation line of Claim 8 further comprising a wrap storage station located below the steam cabinet. The food preparation line of Claim 1 additionally comprising a food ingredient dispenser positioned at the first inside corner.

10

11. The food preparation line of Claim 10, wherein said ingredient dispenser includes a pump mechanism.

12. The food preparation line of Claim 10, wherein said ingredient dispenser includes a metering mechanism to dispense a desired quantity of ingredient.

13. The food preparation line of Claim 10, wherein said ingredient dispenser 5 includes at least one a delivery nozzle located on one side of the dispenser and at least one access opening located another side of the dispenser.

.14. The food preparation line of Claim 13, wherein said ingredient dispenser includes at least one heated container which stores the ingredient before dispensing, and the access opening is arranged to provide access to the heated container.

A food preparation line comprising three sections being positioned to form a generally U-shape counter, the first section and part of the second section forming a first portion and part of the second section and the third section forming a second portion, the first portion abutting the second portion, the first portion including a warmer and a heating device, the warmer and the heating device positioned within generally about six feet of each other so as to be within an arm Tspan of a worker, the second portion including an accompaniments container P.\OPER\DH63282-98 ,s2.doc-2506/01 20 proximate the heating device and a packaging dispenser, the accompaniments container and the packaging dispenser positioned within generally about six feet of each other so as to be within an arm span of a worker.

16. The food preparation line of Claim 15, wherein the warmer is a steam cabinet.

17. The food preparation line of Claim 15 wherein the heating device is a hot ingredient well.

18. The food preparation line of Claim 15, wherein the accompaniments S"container is a produce bin. So co g* 10

19. A food product assembly area comprising a first station and a second o S station, the first station generally located at a juncture between a first counter section and a second counter section and the second station generally located at a juncture between the second counter section and a third counter section, the first counter section, the second counter section and the third counter section arranged 15 in a generally U-shaped configuration, a first storage compartment for a food product base disposed on at least one of the first and second counter sections within arm's reach from the first station, a heating device for a food product component to be applied to the food product base disposed on at least one of the first and second counter sections within arm's reach from the first station, a second storage compartment for a chilled food product component to be applied to at least the food product base disposed on at least one of the second and third counter sections within arm's reach from the second station, and a packaging dispenser disposed on at least one of the second and third counter sections within arm's reach from the second station, the first station and the second station being arranged so as to enable a first worker positioned at the first station to directly pass the food product to a second worker positioned at the second station.

The food product assembly area of Claim 19, wherein the first compartment is a steam cabinet. 4 1* P:\OPER\DH63282-98 rs2.doc-2 601OI -21

21. The food product assembly area of Claim 20 additionally comprising a heated shelf disposed on at least one of the first and second counter sections within arm's reach of the first station.

22. The food product assembly area of Claim 19, wherein the heating device is a steam table.

23. The food product assembly area of Claim 19, wherein the second compartment is a produce bin.

24. The food product assembly area of Claim 19 additionally comprising a food ingredient dispenser disposed on at least one of the first and second counter 10 sections within arm's reach of the first station.

;25. The food product assembly area of Claim 19, wherein the first compartment is a heated shelf.

26. The food product assembly area of Claim 19 additionally comprising at least one electronic display disposed on at least one of the counter sections. 15

27. The food product assembly area of Claim 26, wherein said electronic display is arranged within arm's reach from at least one of the first and second stations.

28. A food preparation line, substantially as hereinbefore described with reference to the drawings.

29. A food product assembly area, substantially as hereinbefore described with reference to the drawings. DATED this 25th day of June, 2001 TACO BELL CORP. By DAVIES COLLISON CAVE Patent Attorneys for the applicant