Logistics and adjacencies have a substantial impact on storage and receiving efficiencies.

Photo courtesy of Ricca Design StudioThe cookline typically becomes the heart of a commercial kitchen and rightfully receives much thought and attention during the design process, but do not underestimate the importance of properly laid out and outfitted storage and receiving areas.

“Procurement is the tip of the spear, as the purchasing managing director’s job is always ahead of the chef’s,” says Michael P. Salvatore, senior director, consulting and customer engagement, Ruck-Shockey Associates, which has offices in Truckee, Calif., and The Woodlands, Texas. “Plus, items need to be held and stored, so it’s key to make these spaces as functional as possible.”

Like many back-of-the-house areas, logistics and location become the primary considerations when designing storage and receiving areas. “When designing, I like to use the zone theory, which puts different areas into zones,” says Brad LaBel, president, LaBel Foodservice Equipment & Design, headquartered in New York City. “Zone 1 is the entry point for ingredients or receiving, while Zone 2 is the prep station with storage that is located by the cooking area. Zone 3 is where food goes out to customers, and Zone 4 is the dishwashing station. Everything coming in the receiving and storage area makes its way through all the zones.”

For both storage and receiving, identical factors come into play. “The size of these areas should be appropriate, so designers need to look at the typical volume to assess necessary square footage,” says Phillip Landgraf, executive principal, Ricca Design Studios, based in Greenwood Village, Colo. “The design also should be scaled to the delivery schedule.”

Receiving Recon

Nahum Goldberg, principal/consultant, NGAssociates Foodservice Consultants, El Cerrito, Calif., first looks at the access for deliveries and trucks. “This should be as close to the kitchen as possible, although sometimes this is not the case in a multilevel building or for airport kiosks that require secure remote areas,” Goldberg says. He recommends including an office
or receiving desk if the size and configuration of the receiving area allows for this, especially in larger-scale operations.

Colorado’s Boulder Valley School District has dedicated areas in its 34,000-plus square foot facility for storage and receiving. The facility delivers 25,000 to 30,000 scratch-made meals daily. Photo by John Jergens Photography“Large-scale operations like commissaries may require forklifts, pallet jacks, hand trucks and charging stations for this equipment,” Goldberg notes. “Proper radius, turns and
clearances should be in place.”

When an operation uses these kinds of materials, safety becomes an even more integral aspect of the design. “We look at the placement of pallet shelving units to ensure there is protection for people walking in the area on foot during pallet loading and unloading,” Goldberg says. “Rapid rollup doors can provide easier access for drivers or staff to access coolers, freezers or dry storage areas.” Smaller-scale operations can incorporate a pass-through area in the design to receive product more easily by the docks, he says.

In addition to verifying proper clearances, Goldberg will typically recommend a covered dock. “For larger operations, consider incorporating fully enclosed docks that have space for multiple truck deliveries without clogging the area,” he says. “Some operations may require 15- to 20-foot-deep docks.”

A receiving area can serve as the space where staff verify the quantity, weight and quality of the orders. “Typically, in a larger operation there will be a check-in station or receiving desk to inspect orders as these come in as well as an area to break down pallets,” Landgraf says. “There also will be a scale for verifying weight, a labeling area and equipment like carts to transport large deliveries.”

Some operators will include a wash-down station for produce in their receiving areas. This can help reduce the amount of dirt and debris that makes its way to the kitchen. Salvatore also recommends a hand sink inside the dock door for an extra level of sanitation.

Dock height for deliveries is another easily overlooked aspect of the receiving area design. “We want to prevent street drops, or product falling to the ground, so manual or automatic dock levelers are an important piece of the puzzle,” Salvatore says. “This is hydraulic to go up and down to accommodate trailers of any height.” Used in substitution of a manual bridge or block plate, dock levelers provide added stability and simplify the delivery process, he adds.

The delivery frequency, as well as the type and size of the operation, will determine how many bays a receiving area requires. Salvatore recommends not overlooking conveniences for delivery personnel, like accessible restrooms. “Vendors are guests, just like customers,” he says.

Assessing Storage

Receiving and storage go hand in hand. Foodservice operators typically segregate kitchen storage areas by type — dry, refrigerated and frozen. “Refrigerated items may be broken down into produce, proteins and seafood,” Landgraf says. “There also may be separate areas for paper goods, chemicals and cleaning supplies.”

Storage methods also come into play with packaging. “High-volume operations may store in bulk, while smaller restaurants will have items in individual cases or bins,” Landgraf explains.

The main objectives with storage areas are temperature control for perishable items and having a system conducive to first in, first out (FIFO) for proper product turnover. “Operators need to practice first in, first out organization,” LaBel says. “If a new delivery comes in, it’s important that it goes behind the older stock so it’s used up and doesn’t go bad.”

Operators can accomplish this by using high-density shelving and can racks. Another primary consideration with design is factoring in enough refrigeration to support the restaurant. “This is what boards of health want to know,” LaBel says. “Putting in a couple reach-in units won’t be able to accommodate higher volumes.”

Even with ambient storage, food safety is a consideration. For example, keep cleaning supplies separate from food items to prevent cross contamination. “Everything needs its own area,” LaBel says. “Also, high-ticket items like liquor should be in a secured and locked location.”

With paper goods, Landgraf likes using dunnage racks, as he feels this is more efficient than shelving. “It’s also important to use vertical space,” LaBel says. “Items used less often will go on the top shelves.”

Can racks and high-density shelving can make the most of storage areas and enhance organization. Photo courtesy of NGA Associates Foodservice ConsultantsIn addition to optimizing space, take into account storage flexibility. “For small- to medium-scale storage needs, we lean toward mobile shelving units, along with mobile dunnage racks, and specialized transport dollies for plate ware and sheet pans are good to have,” Goldberg notes. Also, be sure to understand how local codes apply to storage. “For example, in California, there are unique requirements for restaurants to have a certain percentage or linear feet of storage in relation to kitchen size.”

With back-of-the-house storage areas, it is detrimental to designate too much space that may be wasted. “We don’t give any product more space than it needs to fulfill the operation’s requirements,” Salvatore says. “We don’t want clutter or wasted food.”

To assess space necessary for storage, Salvatore looks at every menu item. “I look at the linear inches of what will be stored to see how many linear feet of shelving is needed,” he explains.

It’s also important to determine how ingredients will leave the storage areas. “Will there be a traditional storage room or open closet that is accessible all day, or is it a two-step requisition system?” Salvatore asks. “Depending on the environment, I like easily adjustable racking and everything on wheels, with shelving that is simple to break down for cleaning and sanitizing.”

Bottom shelves should be a minimum of 6 inches off the floor for cleaning underneath, with a splash guard to protect stored items from cleaning solutions. In coolers and freezers, there should be 18 inches of clearance on top.

Along with space, location is critical since walk-ins and dry storage areas are best situated away from dining areas. Salvatore designs storage areas as close to the dock as possible. “I want my storage areas to be as close to where trucks are bumping the dock with not so much of a gap so there are no pests coming inside.”

When possible, Goldberg designates storage areas for products being redistributed to satellite locations. In some cases, a storage area may be situated by the dock. “This may be for milk cartons or fruit and similar items for schools that are not processed or handled in the commissary kitchen,” he explains. “These can be stored separately and be transferred to distribution trucks to supply satellite serveries or kitchens.”

For added security, receiving offices or desks are typically located by the drop-off zone to prevent theft, Goldberg adds.

Equipment Considerations

In addition to loading equipment, a receiving scale, walk-in coolers and freezers, and shelving, storage and receiving areas benefit from carts and trolleys that can transport ingredients quickly and easily.

“I’m a big fan of track shelving that helps optimize space,” LaBel says. “This is wire shelving that moves back and forth on a track, and we only need one 36-inch entryway. This allows staff to easily move items to gain access to shelves. I also like automated alarms that signify refrigeration is working properly.”

Goldberg notes that high-density shelving systems are compact yet provide 20% to 30% more storage in the space than some other options. “We prefer top rail shelving units rather than tracks on the floor, as this type is less of a tripping hazard and more easily accessed,” he says.

Landgraf says high-density shelving on wheels or tracks adds efficiency as well as palletized racking systems. He adds that environmentally friendly refrigerants such as R-290 and on-demand defrost are energy savers for refrigeration equipment.

“There has been some newer temperature monitoring technology for walk-ins,” Landgraf says. “And I love the opportunity in large production facilities to unload walk-ins from the exterior, with a separate set of doors that open into production areas.”

This allows walk-ins to be loaded with deliveries on one side and unloaded by chefs for processing on the other. “Sliding doors can be more efficient to keep aisleways clear,” Landgraf says. Larger facilities may incorporate robotic dollies for even greater speed, efficiency and labor savings.

“We’re also seeing more ozone generators in cold storage rooms, which can reduce spoilage and prolong produce shelf life,” Goldberg says.

Storage and receiving areas will always have unique layouts predicated on space. “It comes down to how much room can be given up from the kitchen’s operating stations, Salvatore says.