Questions

1. What are the advantages and disadvantages of

purchase specifications for flight caterers, airlines,
and fare-paying passengers?
2. Flight caterers commonly serve multiple airlines.
What implications can this have on inventory
management?
3. Identify the advantages and disadvantages of
branding strategies with an example of a product.
 2.
1.

3. 6.

4. 7.

5. 8.

9.
10.
 QUESTIONS
1. Discuss what the process of new product development
can bring to a flight operation.
1. Crew meals
The obvious policy is to allow crew to eat the same meals as
passengers, especially, since most flights will have some hot meals left
over once passengers have been given a choice
However, there are four problems with this policy
First, if the passenger meal is contaminated with food-poisoning
bacteria, the crew will also be affected.
Second, the menu cycle for passengers may be several weeks.
Third, the crew, especially the cabin crew, are engaged in physical
work.
Finally, in some cases the crew may be working on flights that have
little or no food service, but the flight time, or their shift pattern,
entitles them to a meal or snack, again to keep their energy levels up.
2. Menu cycles
Once product development is complete, a menu cycle is
then decided for a given period of time.
The length of the cycle will be determined by each
individual airline, consideration being given to the time
of the year and to the different foods available.
These menus will be monitored carefully by each
carrier.
Two types of cycle
short-haul flights must, due to the number of occasions
an individual passenger might travel on those routes,
change frequently and the cycle may only last for 7–14
days
long-haul flights, many airlines now have cycles of one or
two months
3. Service and product specifications
The menu planning team would be responsible for
drawing up the dish specifications and standard recipes.
the foodservice team will naturally focus a great deal of
attention on the presentation of food as it reaches the
customer
There are different specifications for individual dishes
(dish specifications) and whole meal trays (meal
specifications).
3.1 Product (or purchasing) specifications
Specifications play an important part in flight feeding
The first step is for the flight provider, often in
conjunction with the airline, to draw up the product
specifications
Once a supplier has been selected, the product
specifications assist in controlling and maintaining
standards
3.2 Standard recipes
The standard recipe is an essential component in flight
food production.
 It is the written formula for producing a food item of a
specified quality and quantity.
 It is essential for control purposes that the standard
specifications are adhered to.
Continue……………..
3.2 Standard recipes
The objectives are to determine the following:
1) quantities and qualities of ingredients to be used,
stating the purchase specification
2) yield obtainable from the recipe and portion control
3) food cost per batch and per portion and hence profit
margins
4) nutritional value of each dish
5) preparation methods required
3.3 Meal specifications
identifies what combination of dishes,
 the respective equipment that is needed to serve a
specific class of passenger on any given flight
3.4 Service specifications
It would include details such as:
the type of service required,
the materials and equipment and procedures to be used
in the provision of that service,
its standard or quality, and the time of delivery, action,
and completion.
Continue…….
3.4 Service specifications

The type and nature of services provided might range from the
provision of a complete catering service to:
1) Ready assembled components of the flight provisions:
wrapped and packaged cutlery sets, ethnic meals, etc.
2) Ready assembled and stocked flight duty-free trolleys
3) The provision of transportation services to deliver the flight
products to the aircraft
4) Laundry service
5) Rubbish disposal
3.5 Packaging and labelling
Packaging requirements are considered in more detail
later but, for example, five different flavors of
preserves might be required.
These could be packed in individual glass jars,
‘gourmet’ aluminum cups, ‘extra cups’ and ‘mini’ cups
 It must protect and maintain the product in the best
possible condition,
it must also be attractive to the consumer.
3.5 Packaging and labelling
It requires different considerations. These include the
following:
Practical Good packaging must work, in that it should
provide the right level of protection for the product,
It needs to contain the product in a convenient
quantity,
The materials used should have no harmful or sensory
effects on the food and be suitable for storage at
chilled and ambient temperatures, or for heating, if
required
 Continue…

Inform Besides the legal requirements, the labelling needs to

be effective and informative, correctly identifying the
product.
It should not be misleading and should provide instructions
for use.
Aesthetics The products must look attractive and fit in with
the overall marketing strategy of the airline.
Emotional appeal The image conveyed by the packaging must
conform with the overall image being developed and portrayed
by the airline.
4. Food and beverage strategies
customers can have ambivalent attitudes towards meals
on board the aircraft and airlines can have very
different views as to the importance, or otherwise, of
on-board service and catering.
 More recently, some airlines have also enhanced the
reputation of their offer by working with celebrity
chefs.
4.1 Use of brands
One way to add value to products is to brand the product
with the airline’s culture, or simply supply passengers
with well-known branded products, thereby taking
advantage of their quality-recognition factor and wide-
spread popularity
brand proposition is a set of statements that summarizes
the combination of positioning and personality and allows
the brand to emerge from the fuzziness of the
competition.
Continue….

The advantages and disadvantages of branding can be

considered from a number of viewpoints
1. Flight catering supplier
 Brand loyalty can be built up thereby ensuring repeat
business and some protection from competition
 Opportunity for premium pricing known as brand equity
2. Flight provider (caterer)
 Purchasing is made easier, particularly when
purchasing overseas and when buying the same brand
 Consistency and uniformity of quality, content, and
performance are assured
 Status and prestige can be derived from using or offering
certain brands
 Product improvements are encouraged
3. Airline
 Branding adds to and helps reinforce the effects of other
advertising
 Helps the airline build a reputation for quality
 Consistency and uniformity of quality and content
 Helps facilitate the introduction of new lines or ideas
 Provides prestige value
 Provides visible signals of positional strength in the
market place
4. Airline passenger
 Provides identity and focus for the airline
 Provides the airline passenger with some reassurance
 Prestige value can be attached to products from another
class
 A branded product may produce a side effect on a
different segment of customers
5. Celebrity chefs
 Bringing a knowledge of food trends, these culinary
advisors have been instrumental in developing dishes
that are contemporary
Opportunities for variety and fresh preparation attract
more chefs to flight kitchens,
These difficulties and complexities are often not
realized by celebrity chefs, who may be narrowly
focused when trying to develop specialty cuisine on
board the aircraft.
Chefs on board
One strategy is to have a chef on board to cook the food
in a restaurant service style.
6. Book the cook
Another method is to order the main course in advance
 Through the reservations office or the travel agent, the
order can be placed by simply selecting from the list of
‘Book the Cook’ dishes at least 24 hours before flight
departure.
7. Gate-house service
in which passengers pick up their food selections,
packaged in a branded bag with handles just prior to
boarding.
 The benefit is to save labor and time on board, but
some caterers are skeptical about the concept
8.Meal coupons
 This initiative is to offer passengers a discount meal
coupon redeemable in their airport concessions, instead
of providing a flight meal.
 Activity
Branding Service specification Special
Meal specification meals Standard recipe
Menu cycles
Menu design
Menu development
Menu planning
Product performance
Product specification
 Activity

1. Discuss the menu considerations in planning an in-

flight meal and compare them with a current sample
in-flight menu.
2. Discuss what the process of new product development
can bring to a flight operation.
3. Discuss the complexities of the demand for special
meals.
4. Identify the advantages and disadvantages of branding
strategies with an example of a product.
Flight catering supply chain
and inventory management
Introduction
The supply chain as a concept is relatively new
 But some suggest that the concept is already outdated,
for two reasons.
 First, it is more appropriate from a business
perspective to think of these relationships and flows
between organizations as a ‘value chain’
 Second, the notion of a ‘chain’ is too simplistic; in
reality, supplier relationships are typically a complex
network.
From this we can identify a number of issues which need
to be managed:
• ordering and specification of products from suppliers
• physical handling, distribution, delivery and receipt of
products
• identification of value-added elements
• holding of inventory to buffer against uncertainty
• minimizing stock levels to reduce storage costs, avoid
waste, and help cash flow
• integrating activity and building relationships across a
network
Role of food and drink manufacturers
1. Adapting existing or developing new products
 Manufacturers need then to develop, sell to and keep
satisfied two distinct customers—the caterer and the
airline—
When seeking to develop a new product, manufacturers
need to consider a number of additional factors that
would not normally be considered in the product
development process for other commercial catering
outlets
2. Supplier responsibilities and provision
The role of the flight suppliers is to provide the flight
caterers with goods and services of a consistent and
uniform standard and quality, according to specifications
that have been agreed by both the caterers and the
airlines.
Suppliers have a number of responsibilities that are legal or
contractual and also have moral connotation
Many of the responsibilities of the supplier in the provision
of goods and services have already been agreed and are
contained in the Airline Catering
Code of Good Practice
Cont…..
 Airline Catering Code of Good Practice (Airline Caterers
Technical Coordination Committee, 1990) which
requires that:
“All materials must be purchased from reputable
suppliers with acceptable hygiene standards. Suppliers’
premises and processes should be inspected by
competent persons reporting to the catering company,
to ensure that satisfactory standards of hygiene are
maintained.”
3. Purchasing of flight consumables and non-
consumables
When considering the purchasing and sourcing of flight
consumables and non-consumables, many factors over
and above those associated with conventional catering
operations need to be considered.
Indigenous products Passengers flying their own national
carriers invariably like and expect to see indigenous foods
on those flights.
Sensitive products On some flights the origin and nature
of the product must be considered in relation to the flight
destination
4. Supplier relationships

Both parties have responsibilities that must be carried

out to assure proper food safety and quality
 Operators with larger annual sales had a larger number
of suppliers.
It made no difference if the organization was a retail,
hotel or institutional food service.
Cont..
The six most important characteristics, across all types of
organization, that were identified were:
• accuracy of filling orders
• consistent quality level
• on-time delivery
• willingness to work together to resolve problems
• willingness to respond in a ‘pinch’
• reasonable unit cost
Cont..
Institutional food service operators and the larger firms
(probably flight caterers too) were also concerned about:
• reasonable minimum orders
• volume discounts
• frequency of delivery
• payment policies
4.1. Supplier negotiation
The basis of satisfactory negotiation is that both parties
feel happy about the deal they have struck
Suppliers are more likely to negotiate a price if they
recognize that the catering manager is really price
conscious
Alternatively, discounts may be agreed upon for bulk
purchases or prompt payment
Cont…

4.2. Supplier responsibilities during recalls and investigations

Any food safety problem must be notified to the flight
caterer as well as possible problems being investigated by
regulatory officials
All suspected products under investigation must be
immediately recalled. Suppliers, therefore, are expected
to have recall procedures in place.
Open coding systems are preferable, i.e. systems that are
simple to understand by anyone since they can also assist
with stock rotation.
4.3. Supplier audits
Hygiene and sanitation inspections should be both
announced and unannounced.
These inspections should be seen as positive
arrangements inviting opportunities to discuss quality
aspects of provision
5. Purchasing specifications
 determine what is required in relation to purchases
 vary greatly in relation to the depth of information
they contain.
come in a number of different forms: food, nonfood,
contract, and service.
 the expectations of a product’s level of quality or
safety may be dictated by airline specifications and
these are, generally, found in the catering manual for
that airline.
6.Inventory management
“inventory management is one of the greatest
challenges facing an in-flight caterer”.
There are a number of reasons for this:
airlines operate menu cycles so, ingredients and
products are changing regularly
caterers are likely to have contracts with several
airlines, each of which is likely to have different
product specifications
7. Receipt of goods inwards
Usually a separate delivery entry is used to unload
goods from delivery vehicles.
Usually a separate delivery entry is used to unload
goods from delivery vehicles;
All incoming supplies must be checked for hygienic
delivery and condition by a trained person.
Upon delivery, all potentially hazardous food must be
refrigerated first.
All supplies must be stored and used with the first in,
first out system
Therefore, suppliers of potentially hazardous foods
should be able to supply upon request such data as:

• the maximum refrigerated shelf-life at 7.2°C

• the maximum allowable time at 12.7°C
• the maximum allowable time at 21°C
8. Storage areas
Specialized storage areas are required for a wide range of food and
non-food materials.
Food materials generally include:
• fresh fruit and vegetables
• frozen fruit and vegetables
• fresh fish/seafood
• frozen fish/seafood
• raw meats
• cooked meats
• dairy products
• dry goods
• bonded alcoholic beverages
8.1 Dry stores
There are three main ways in which dry goods, either
consumables or non consumables, may be stored:
Shelving is used for items that are individually packed
in some way, such as packets, jars or cans.
There are three types of shelving.
Fixed shelving is permanently fixed to the wall or floor;
static shelving is self-standing on legs; and
mobile shelving is self-standing but on wheels or
casters.
Bins are used to store items that may be delivered in
paper or cardboard containers but need to be protected
from infestation either by insects or rodents.
The term ‘bin’ is also used to describe how bottled
wine is stored.

Palletized storage occurs in very large-scale operations.

A pallet is a wooden platform that can easily be moved
by a forklift truck on which goods are stored in bulk,
usually in boxes or cases
8.2 Refrigerated storage
Chillers are designed to hold stored materials at a
temperature of between 1°C and 3°C, whereas
freezers hold frozen goods at a temperature of –20°C.
Two main types of chiller or freezer
Cabinet chillers or freezers have a front opening door
with interior shelving.
Walk-in chillers or freezers are usually made from
urethane foam 10 cm thick sandwiched between two
sheets of metal, such as unpainted or painted
aluminum, steel or stainless steel.
The efficiency of operating and maintaining
refrigerated storage is affected by many factors:
Amount of insulation Over time door seals and rubber
‘grommets’ may wear and lead to tiny but continuous
leaks
Efficiency of air flow Fans assist airflow to ensure a
consistent temperature throughout the unit
Items stored in the unit Any item placed in the unit
that is above the temperature of the refrigerated
space will raise the overall temperature in the unit
Cont…
Number of doors and frequency of opening Normal
usage is assumed to be six to eight openings per 8-
hour shift.
 Surrounding environment Refrigeration should not be
placed near sources of heat, including direct sunlight.
 Efficiency of the evaporator As this is cold, air
moisture will freeze on it making it less efficient.
9. Safe and secure storage
The basic aim of the storage system is to ensure no
loss of value in goods purchased. Such losses may be
of two types, spoilage or theft.
Spoilage can be prevented by adherence to some basic
principles, as follows.
Stock rotation—goods are used in sequence, the older
items first, to ensure that they are consumed while
still in prime condition.
Stock separation—goods that might contaminate each
other, even if just by odor (such as fish tainting dairy
products), must be stored separately, if not in their
own fridge, at least in sealed containers on separate
shelves.
 Sanitation—to avoid cross-contamination, both the
store areas must be kept clean and stores operatives
must comply with good hygiene practices.
Cont….
Temperature monitoring—the temperature in each main
type of storage area— ambient, chilled, and frozen—must
be monitored to ensure it is maintained correctly, and if
a fault is detected it must be repaired immediately.
Safe handling—items must be handled and transported
safely to avoid breakages.
Prevention of infestation—insects and rodents must be
prevented from entering storage areas through the
maintenance of floors, walls, and ceilings, the closures
and screens on windows and doors, and specific
equipment such as ultra-violet fly killers.
The security of goods can be threatened by anyone
who gains access to the stores.
Security systems include:
Bar codes—In flight catering, the computerization of
inventory control through the use of bar codes, has
made it possible to have a ‘perpetual inventory’
 Stock-taking—This is the physical alternative to
perpetual inventory, i.e. maintaining a physical count
of all stock items on a regular basis.

Locks and keys—Another obvious security measure is
to ensure that goods are stored in a space that is
locked when not in use.
 Rubbish compactors—Storage areas produce a large
amount of paper waste in the form of cardboard
boxes and packaging materials. The also facilitates
waste handling and recycling
Employee entrance security This is to ensure security
for aircraft in flight as well as in the production unit
itself .

Premises surveillance—While access to storage area

should always be limited and controlled, a further
deterrent is provided by the use of closed circuit
television (CCTV).
9.1 Stock valuation and stocktaking
There are four methods of stock valuation, which can be
summarized as:
FIFO (first-in, first-out)—which tends to give the highest
value to stocks and to inflate profits
LIFO (last-in, first out)—which tends to undervalue stocks,
with a more realistic profit valuation
AVERAGE—which tends to overvalue stocks and
consequently overstates profit; it has the advantage of
being administratively convenient
STANDARD—which is a sophisticated technique forming the
basis for a comprehensive cost control system
9.2 Investigating stock control problems

 ‘ghost’ supplies refers to goods for which the

operator is charged but which are never received.

 Poor stock rotation leads to wastage, as perishable

items may deteriorate before they are used, and tins
or jars may be held onto beyond their ‘use-by date’
 Breakages also create losses if goods are stolen, there
will be a stock discrepancy.
 Theft may be carried out by trespassers on the
premises who do not have the authorization to be
there, or by dishonest employees.
 Unauthorized consumption, i.e. eating or drinking
items that have not been provided to them.
 Discussion questions
1. What are the fundamental characteristics of
developing good supplier relationships?
2. What are the advantages and disadvantages of
purchase specifications for flight caterers, airlines,
and fare-paying passengers?
3. Flight caterers commonly serve multiple airlines.
What implications can this have on inventory
management?
Flight production facilities and systems planning

Introduction
A catering system has to be designed and organized to
produce the right quantity of food at the correct standard
Such an approach to design provides:
• in-depth analysis of functional requirements
• integrated thinking
• enhancement of knowledge base
• effective flow
• balance between all stages of the process
Principles of flight production unit design
Three key concepts all relate to improving unit
productivity. These are:
• decrease in the volume of in-process materials (just-in-
time approach)
• improving labor productivity
• waste reduction
The method by which food and associated items may be
handled or processed varies from unit to unit depending
on their production system.
The three main production philosophies are:
• Batch production
• Continuous (flow) production
• Cell production
Batch production
 is based on the premise that a small quantity is
produced at one time and only when required.
 Speed and consistency are the advantages.
Continuous (flow) production
 is based on high volume utilization of equipment.
Identical meals are produced in large numbers and then
allocated to flights afterward.
 This process works best in flight production units
producing very large numbers of meals for only one
airline.
Cell production
Many flight production systems design is based on the
cellular manufacturing principle, which is the grouping
of machines and equipment into configurations related
to each family or each part.
 the quality of product can vary depending on the
individual and it requires a high level of supervision and
planning.
Production kitchens
Flight catering companies normally use a modified cook-
chill system for the preparation and storage of cooked
items.
 Flexible cooking technology based on highcapacity
cooking equipment (Bratt pans, combination ovens,
convection ovens, pressurised steamers, etc.)
Fruit and vegetable preparation
 This area requires sinks for washing vegetables together
with stainless steel.
Prepared materials are packed into plastic boxes ready
for transfer to the hot or cold kitchen.
Meat preparation
This area requires similar equipment to the vegetable
preparation area, with specialized preparation
equipment including mincing machines, bowl choppers,
and dicing machines.
 Once raw meats have been prepared, they are
transferred to plastic storage boxes and held in
refrigerated storage until required by the hot kitchen.
Fish preparation
This is very similar to the meat preparation area in
terms of the basic requirements.
 It is essential to ensure that the preparations of raw
and cooked items are completely separated.
Hot kitchen
This area makes use of large-scale batch production
equipment, such as boiling pans, Bratt pans, pressurized
bratt pans, convection ovens, and combination ovens.
large-scale equipment, which is used for the majority of
the production
Cold kitchen/larder
This kitchen is used for the preparation of hors
d’oeuvres, cold meats, sandwiches, salads, and other
larder items.
 Cooked meats may be delivered (chilled to below 5°C)
or they may be purchased ready cooked
Bakery/pastry
This part of the preparation area covers the making of
all desserts and baked goods.
Utensil washing
This facility is totally separate from that used to handle
flight returns.
Often, the cleaning system is designed into the building
to allow for spray jet or foam cleaning breaks in
production.
Test kitchen
may be required in order to evaluate new recipes and to
carry out routine testing of dishes.
 In the test kitchen, foods can be produced on a small
scale, but using the same types of catering equipment
as used in the main production kitchen.
Beverage preparation
Some smaller or older aircraft do not have facilities for
making hot beverages on board and there may be a
need for a beverage section which prepares hot water
and fresh coffee, which is loaded into specialized heat-
retaining containers.
 Discussion questions
1. Design a flow of an in-flight kitchen and discuss
which stages of the process can provide added value.
What are the challenges?
2. Discuss the relative advantages and disadvantages of
each different type of production method.
Flight catering
operations and
organization
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