How to choose the right oven for store, menu BY ABBIE WESTRA | [email protected]

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ave you hugged your equipment manufacturer lately? Because it seems as if recent breakthroughs in cooking technology have all been done with you in mind. These milestones have opened the door for c-store retailers to offer a wider variety of foods using less labor and space. But what are the differences between them? Which piece of equipment is best suited for your food program? Advancements in accelerated-cooking technology allow retailers to make high-quality hot foods in a limited-service format. Be it a TurboChef, Merrychef or some other chef, these ovens quickly zap countless kinds of food from hundreds of programmed recipes, often without the need for a ventilation system. “Then and now, I still call it transformational,” says Stan Frankenthaler, executive chef for Dunkin’ Brands, Canton, Mass. In 2007 Frankenthaler helped roll out an oven-toasted sandwich platform using the TurboChef Tornado oven. “It helped transform the restaurants, it helped transform the menu and it gives us a lot of opportunity for the future.” But an accelerated-cooking oven may be all wrong for you. Perhaps your store is best suited for a combination (combi) oven—a technology that may be intimidating at first go, but which has been used widely in Europe for decades. New countertop mini combis work well for c-store applications. “At [the new baseball stadium] Target Field in Minneapolis, we have small combi ovens in the majority of our concession stands,” says John DePaola, a combi proponent and managing principal for Foodservice Resources, a design and management firm in Fredericksburg, Va. “We plan to use the combi ovens to bake pretzels, steam hot dogs, rethermalize prepared food and prepare specialty offerings like

pork chop on a stick or beer-braised bratwurst.” Or what about the trusty conveyor oven, which has been upgraded with user-friendly functions and a technology referred to as “air fingers”? Even microwaves have advanced beyond their perceptions as residential popcorn-poppers.

Your Foodservice Future The greatest mistake a retailer can make is purchasing a piece of equipment without first considering what the menu is and, more important, what the retailer wants it to be. Equipment should be flexible to evolving menus, even opening up new profit centers such as breakfast sandwiches, or a latenight-munchies menu. Before you know it, you may be doing dinner entrees. (Four salmon fillets in 120 seconds in a Merrychef 402S is fast food indeed.) “I once knew a banker, and he wrote loans for people who were opening restaurants,” says Mike Matthies, project manager for Frank Redmond Associates, a Phoenix-based company that executes food-facilities planning for higher education, c-stores and more. “He always said, ‘I would never approve a loan if somebody couldn’t close on Friday and open on Monday under a different name.’ ” Cooking equipment should be similarly adaptable. Multi-functionality has been a big focus for equipment manufacturers in recent years, and retailers should look at equipment pieces that will perform multiple tasks throughout the day. Perhaps you shouldn’t buy a mini combi oven just to batch-cook french fries; but if you’re also using that combi to cook parbaked breads, bake brownies bites, prepare chicken tenders and cook and hold breakfast sausage patties, then the ability to bake January 2010

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french fries may be another reason to make the purchase. Alison Cullin-Woodcock, corporate executive chef for Tampa, Fla.-based Manitowoc Foodservice, recommends retailers look at a new equipment purchase not in isolation, but as a “composite piece of money-making real estate.” “You have to look at it in tandem with the other pieces you might already have in your store,” she says. “Can you use an underutilized item more by adding another piece of equipment? “ In the simplest terms, it’s a question of output vs. volume.

Combi ovens are ideal for batch production and can hold items after cooking at the desired temperature. Acceleratedcooking ovens should be used for immediate consumption of one-at-a-time items (though a quality holding unit complements a fast-bake oven well). Conveyor ovens, meanwhile, are best used for continuous, automated production. Estimate your finances and return on investment, ask the right questions, think about the future of your menu and test-drive any equipment before choosing the best cooking technology for your operation.

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Equipment Comparison ACCELERATED-COOKING OVENS How It Works: A convection fan pulls in air and heats it through impingement plates (which speeds up the heat transfer) for an even heat pattern and a browned exterior. Meanwhile, the microwave function uses moisture in the food to heat the products from the inside while keeping them moist. All three elements can be used together or individually depending on the product being cooked. Key Features: 䊳 Cooks up to 15% faster than conventional convection ovens. 䊳 Most can be programmed with hundreds of recipes (with different cook stages) across all stores. 䊳 Built-in catalytic converters mean operators don’t need a ventilation system. 䊳 Metal cookware can be used inside the oven, even with microwaves. When Not to Use One: Accelerated-cooking ovens are not ideal for cook-and-hold applications, nor any ingredients or menu items cooked in batches. Key Players: Amana AXP20; Merrychef 402S and EC503; TurboChef’s suite of accelerated-cooking ovens. Price Range (list price): $6,000-13,000

TurboChef C3

COMBI OVENS How It Works: These ovens cook using steam, convection heat or a combination of the two. In the convection mode, the oven circulates blasts of dry heat, ideal for pastries and breads. The steam mode injects water into the cabinet for moist cooking. The combination mode uses both dry heat and steam to maintain exact humidity levels, keeping food moist, reducing shrinkage of product and yielding consistent results time after time. Key Features: 䊳 Once relegated to high-volume hotels or schools, new countertop models allow small retailers to try out the various cooking applications of a combi oven. 䊳 Programmable with hundreds of recipes and multiple steps per recipe. 䊳 Most countertop models feature a boilerless injection system for steam, and some models, such as the Electrolux Libero mini combi, requires no water or drain connections. Electrolux Libero mini combi When Not to Use One: Combis take time and manpower to master all the functionality, so a dedicated foodservice manager should take on the project and properly train store-level employees. Cook times are longer in a combi, so it is not ideal for heat-to-order applications. Key Players: Cleveland mini combi oven-steamer, Electrolux Libero Line mini combi 䊳 Cleveland mini features the following cooking modes: steam, hot air, slow cooking, Crisp and Tasty (de-moisturizing), combi, retherm and cook and hold. 䊳 Electrolux Libero mini combi features the following cooking modes: max steam, low steam, combi cooking, convection heat and cooling function (for transitioning between cooking functions). Price Range (list price): approximately $3,000-$10,000

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CONVEYOR OVENS How It Works: Food travels horizontally through a heated cabinet on a conveyor belt. Technology such as impingement heat delivers jets of hot air to the top and bottom of the food. Key Features: 䊳 New technology delivers faster bake times, a thoroughly baked surface, improved texture and crisping, and higher yields with greater moisture retention. 䊳 Conveyor ovens offer consistency, helpful in keeping food waste down. 䊳 Conveyor ovens are a familiar format and easy for store-level employees to run. When Not to Use One: Conveyors are great for continuous output, when you have an employee manning the oven at all times. If you don’t need continuous output, consider a smaller conveyor toaster. They also take up more space than accelerated-cooking ovens and mini combis. Key Players: Lincoln FastBake Impinger Oven; Savory’s Synergy Conveyor Toaster; TurboChef’s HhC2020 Price Range (list price; countertop models): approximately $4,000-9,000

Lincoln countertop Impinger FastBake Oven

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The Right Cooking Method DESSERTS: Prepare batches in a combi oven; heat individual orders in an

Products such as focaccia are made with oil, which helps keep the product

accelerated-cooking oven.

from drying out.

FRENCH FRIES: Deep fat fryers are never going away, but combi ovens are

HOT POCKETS: One 4-ounce Hot Pocket cooks in 10 minutes in a mini combi,

a good solution for operations without the manpower for complete oil/fryer

or two minutes, 15 seconds in an accelerated-cooking oven.

maintenance, or the necessary fire and safety precautions. This is especially true if you are leaning toward a combi to complete other cooking tasks. A

ONION RINGS: One fry basket cooks in 5 minutes in a mini combi such as

combi oven can cook a batch of fries in 8 minutes.

the Convotherm; six pieces cook in one minute in an accelerated-cooking oven such as the Merrychef.

TOASTED SUBS: Part of the decision is based on output and volume: continuous heating vs. one-at-a-time. For example, Potbelly Sandwich Works,

HASHBROWN STICKS: A 12-piece batch cooks in 12 minutes in the mini

where all the subs are toasted, uses conveyor ovens; Subway, which has just

combi; a 6-ounce portion cooks in three minutes, 30 seconds in a Merrychef.

a few toasted subs on the menu, uses accelerated-cooking ovens. Labor is also a factor. Conveyors require more hands-on labor to grab the sandwich off the belt, while accelerated ovens are less automated, and require more technical attention than a conveyor. Accelerated-cooking ovens often take less time because it’s heating the sandwich within a self-contained cavity, whereas conveyor ovens offer consistency sub after sub. The conveyor sub will yield a drier, crisper sandwich due to the direct heat, whereas accelerated-cooking ovens use microwave technology, “so you’re actually aggravating the moisture molecules to create heat, keeping it moist,” says Alison Cullin-Woodcock, corporate chef for Manitowoc. “It really depends on what the gold standard is for the products you are going to serve.”

BREADS: Par-baked and thaw-and-serve bread products work well in mini combis or accelerated-cooking ovens; it all depends on output speed (accelerated-cooking ovens) vs. volume (combi ovens). Also, look beyond the traditional roll or bun. Pita bread, naan and other flatbreads are actually more forgiving that breads and rolls because they were designed to stay moist and warm longer, and they’re very portable as well.

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Life-Cycle Costing and Equipment Financing Life-cycle costing allows you to determine the total cost of operating a piece of equipment over its service life. For example, if your existing conveyor oven costs $1,000 in kilowatt hours per year to operate and you buy a new oven for $5,000 that costs $500 per year to operate, that’s a 10-year payback. However, if you start offering breakfast sandwiches for the first time thanks to this new oven, your payback is that much faster because of the new revenue channel it helped open. Visit www.fishnick.com/saveenergy/tools/calculators for free life-cycle costing calculators. In terms of the lifespan of your equipment, longer isn’t necessarily better. It depends on the type of operation you run and the frequency at which your menu changes. For a commissary setting, long-lasting equipment (10 to 15 years) makes the most sense. For a small, on-site operation, “you’re probably going to renovate that store in five years or so, because the market is going to change,” says Mike Matthies, project manager for Frank Redmond Associates. “So for those kinds of operations, maybe don’t invest in the 10- to 15-year piece of equipment.” Matthies tells people to amortize their capital investments over a three- to five-year period: “It’s pretty hard to amortize it in less than three years, because it affects your profit and loss statement.” At the same time, “you don’t want to still be paying for stuff when it starts to break down.” He also recommends putting money away so when the piece of equipment’s lifetime is up, money has already been accrued and you can buy the new equipment and start amortizing it.

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All Bases Covered Questions to ask yourself and your equipment rep, from Alison Cullin-Woodcock, corporate chef for Manitowoc Foodservice: 䊳 How much space will the equipment piece take up? 䊳 Can I stack the equipment if I am looking at a small space of

40 square inches or less? 䊳 Do I need water, power and/or a drain? 䊳 Do I need a stand, or will this fit on an existing counter? 䊳 Do I need extraction/ventilation? 䊳 Do I need extra cooling/freezing storage? Could I have a base

unit that doubled as a cooler/freezer and a stand for the oven?

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Cooking Technology, Defined

䊳 What accessories come with the ovens? Do I need special

䊳 Air Impingement: The type of heat transfer often used in

pans, tools or trays?

conveyor ovens, particularly for the cooking of pizzas and subs. Air jets direct columns of high-velocity, heated air perpendicular to the food surface as the food travels through the oven on a wire mesh conveyor. These “air fingers” that create the air flow are positioned below and above the conveyor. 䊳 Catalytic converter: This converts the fumes created by an oven into a less-harmful form. Having an oven equipped with a catalytic converter eliminates the need for a ventilation system. 䊳 Combi Ovens: Ovens that cooks using steam, convection heat or a combination of the two. In the convection mode, the oven circulates blasts of dry heat around the cabinet. The steam mode injects water into the oven for moist heat. The combination mode uses both dry heat and steam to maintain exact humidity levels. 䊳 Convection: Baking technology that uses fans to force air around the cooking cavity to ensure even cooking. 䊳 Microwaves: Used in accelerated-cooking ovens in tandem with impinger heat and/or convection heat to cook the inside of products for moist, even results.

䊳 What products might I want to cook, how am I am going to

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cook them and how often? 䊳 Will I cook and serve, or cook and hold? 䊳 If I cook and hold, do I have a holding or display case to

merchandise the food? 䊳 How easy is it to clean? What chemicals are needed, and how

do I buy them? 䊳 How easy is it to use? Can it be fully pre-programmed with

all my food recipes? Can it be locked to prevent staff from tampering with it? 䊳 How much staff training will be necessary? 䊳 Who’s going to operate this cooking system? How tall are they?

Do I need to lower the base units (the average foodservice operator is 5 feet 4 inches)? 䊳 What else can the equipment do for me?

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Making the Most of Little Space

that route, we’d have to reoutfit the entire space (for a hood),” he says. “That

Prepared foods weren’t even a consideration for single-store retailer Greg

wouldn’t have been feasible for us.”

Horos when he opened Locali (above) in Los Angeles early last year. “Originally,

Locali’s funky, “conscious-convenience” menu features sandwiches such

we just wanted it to be a convenience store; we didn’t envision it being a deli

as The Franklin Phenomenon: turkey, Monterey jack, spinach, tomato and red

or prep area because we simply didn’t have the space,” he says of his 675-

onion slathered with chipotle sauce on a pretzel bun. The Log Cabin breakfast

square foot store. California’s strict ventilation regulations also deterred Horos

sandwich tops a butter croissant with smoked chicken, sliced apple, Swiss

from initially diving into foodservice.

cheese and maple syrup.

But, he thought, why not make up some sandwiches on a simple prep

In line with the store’s overall mission—Horos describes it as “if Whole

table? “And lo and behold, a month and a half in, we realized that our deli

Foods and 7-Eleven had a love child”—Locali’s cooking equipment has a

was the biggest part of our sales,” he says. “It’s almost 75% of our business.”

low environmental footprint. The oven is a “recycled” Anvil that Horos

The little kitchen is now equipped with a panini grill, a small range top

bought from a local company that refurbishes used commercial cooking

for soups, and a convection oven used to bake the few items that need it

equipment. “It’s less expensive, and it’s just very wasteful when it all goes

(such as the “bomb baked potatoes”)— all with no open flames. “If we went

to a junkyard,” he says.

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䊳 To get the fastest ROI, look for equipment pieces that will perform multiple tasks throughout the day. 䊳 Think about where you want your foodservice program to be in the future, and purchase an oven than can adapt to evolving

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menus. 䊳 Look at potential cooking equipment in tandem with other equipment pieces: Can you use an underused item more by adding another piece of equipment? 䊳 Test-drive all cooking equipment before making a purchase. Test your foods as well as other menu items you hope to market in the future.

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