Whether located in the front or back of the house, the main goal of a sandwich make station is simply to keep pace.

“Rather than locating the make station in the back of house, more operators are seeking more of a show out front.” Brent Hall, Clevenger Associates“For maximum throughput, we want the sandwich maker pivoting, rather than taking steps, to access ingredients and packing materials,” says Gary Jacobs, principal, Jacobs Doland Beer, New York City. “Labor modeling is critical, so these stations must be flexible enough to handle peak and off-peak volumes with scalable staffing.”

For make stations in the front of the house, the focus is on the customer’s experience. “Rather than locating the make station in the back of house, more operators are seeking more of a show out front,” says Brent Hall, principal/president, Clevenger Associates, Elma, Wash. “This way, operators can cook their own bread so customers can smell and see it or implement fresh carvery stations that emphasize quality.”

Also, sandwich make lines fulfill a purpose that varies, depending on the operation. “For example, is this a small neighborhood concept or a big catering outfit? Are sandwiches made to order or is there a prescribed menu?” asks Arlene Spiegel, president, Arlene Spiegel & Associates, New York City. A sandwich makeline is not just equipment with cold drawers and bins on top, she adds, explaining that it should fit into the concept’s menu requirements.

Primary Considerations

As with any station, the menu makeup, along with the operation’s anticipated volume, will dictate the design. The number of sandwich options also comes into play. “This includes how many types of bread, since each will need a home, as well as the different ingredients,” says Ken Schwartz, president, SSA Foodservice Design + Consulting, Tampa, Fla. “With the product mix, will ham and Swiss sandwiches comprise 70% of sales and chicken salad just 5%?”

It’s also important to note that a best-in-class layout for a given operation does not necessarily require a linear format. “Sandwich stations may not be straight lines but U-shaped,” Schwartz notes. “Regardless, everything needed for prep should be located at arm’s length.”

This includes an accessible refrigerated rail for toppings, refrigeration below with extra ingredients and an area for storing dry or ambient products like bread. “Along with the building process, the design needs to take into account how sandwiches will be served,” Schwartz notes. “Will these be wrapped in deli paper, plated or presented in a basket?”

These serving materials will need a home, which may include accessible shelving within the station. “The first things we discuss are the menu in terms of breadth and the number of breads, spreads and meats; the number of hot and cold sandwiches; how many will be made to order; and what meat is presliced,” Spiegel says. “Sandwich shops are an organized act of engineering, and consistency is needed since everything is done according to measurements.”

Space allocation in this station also depends on volume. This will dictate equipment size and the types necessary. “Although sandwich tables are typically 48 inches long, some operations will incorporate two 60-inch-long tables if volume is high,” Hall says.

A number of other design questions are always on Spiegel’s radar: Will bread be grilled on a flattop? Will cheese melting be necessary in a salamander? Where will scraps and waste go? What will be the overall tasks of the sandwich maker? Will they prepare other items, such as soup or salad on the side? Answers to these questions will play a vital role in determining the layout of a sandwich line.

“Sandwich shops are an organized act of engineering, and consistency is needed since everything is done according to measurements.” Arlene Spiegel, Arlene Spiegel & Associates

Looking at Logistics

Though most sandwich make stations generally use similar equipment, menu and overall concept will drive some variations from one operation to the next. “Some operators prefer refrigerated drawers with pans for storing ingredients, while others prefer using doors, and some like a mix of the two,” Hall says.

Condiments also can be distributed in different ways. Some utilize squeeze bottles for mustard, ketchup, mayo and other toppings, while others would rather use a spreader and pan or some other container. “Hot proteins will require heated food wells,” Hall says. “Exhibition make lines in view of customers may keep meat in induction warmers with upscale pans for appealing displays.”

This station may also require other heating and warming equipment. “Speed ovens have become essential for warming or toasting bread,” Hall says. “These are faster than conveyor ovens or pop-up toasters.”

Some designs will allocate space below the counter for plates and/or
sandwich wrapping materials. If the make station is remote from the kitchen, hand sinks will be necessary, as well as a dishwashing area to clean utensils. Backup as well as duplicate ingredient storage is also essential for high-volume operations.

“We often design two-person stations with shared common ingredients like lettuce and tomatoes in the center section of the cold pan then duplicate fillings and less common cold/dry items and cutting/wrapping stations on each side,” Jacobs says. “Depending on the menu, hot items can be held in bains-marie, warming drawers or cabinets, or in specialized equipment such as vertical broilers for gyros and steam boxes for hot pastrami and corned beef. Certain items are best held cold and rethermed in microwave convection ovens, panini presses or countertop ovens to avoid drying out, overcooking or otherwise reducing quality.”

“Sandwich stations may not be straight lines but U-shaped. Regardless, everything needed for prep should be located at arm’s length.” Ken Schwartz, SSA Foodservice Design + ConsultingIn terms of speed of service, utilizing vertical space helps increase efficiency, as the more horizontal the station is, the more steps staff will be taking. “Logistics and storage are critical, along with how things are laid out or the ergonomics,” Spiegel says. “Creating an efficient and effective layout ensures the key sandwich make people can greet guests when in the front of house. Every time staff has to leave this station it impacts efficiency.”

Essential Equipment

From a labor standpoint, outfitting the station with the appropriate equipment makes a difference when it comes to design. “Instead of just one, I would rather have two strategically placed make stations with two to three counter people, so they are not walking back and forth or causing bottlenecks,” Spiegel says. “The front line is made to order, while the back line has all the accoutrements like toppings and condiments.”

Spiegel adds that, for large catering orders or preorders from third parties, operators can designate a duplicate area in the back of the house to serve as the sandwich make station. “A current sandwich make station we designed includes three hot carve counter stations on the front line and another station on the back line just for pickup orders,” Spiegel says. “If it’s a sandwich shop, there should be an area for grab-and-go items, which will require a refrigerated cold merchandiser for sides.”

Equipment functionality and maintaining food temperature are key with make station design. In addition to cold drawers at the bottom of the prep table for backup ingredients, Spiegel will include a griddle or flattop with warming drawers underneath at an adjacent hot station for hot meat. “Some meats may need to be held hot in a steam table, but we’ll cook or retherm it in the back of house,” Spiegel says. “So we’ll want backup meat in a hot holding cabinet that’s typically on casters [to move where needed].”

“When the station is guest facing, there’s a greater focus on sightlines and not having the server turning their back.” Gary Jacobs, Jacobs Doland BeerJacobs recommends storing all sandwich ingredients, including cold toppings and hot meat, in separate thermostat zones for proper temperature maintenance. “We generally spec separate thermostats for ingredient rails and below-counter refrigeration, as the rails are exposed to room temperature air during peak periods,” Jacobs says. “Hot-held ingredients should also be at different temps where appropriate and possible.”

In addition to hot wells for holding, sandwiches also may require panini grills and salamanders for melting cheese. “If not presliced, meat and cheese will require several slicers designated for specific products,” Spiegel explains. “For example, pastrami will not use the same slicer as salami or turkey.”

For accurate portion control, use scales to weigh meat and cheese and scoops to dole out consistent amounts of tuna, egg and chicken salads. “When the station is guest facing, there’s a greater focus on sightlines and not having the server turning their back,” Jacobs says. “Slicing to order, particularly by hand, looks best on the front counter.”

An appropriate amount of bread storage for the different types offered, typically between three to four, should be part of the equipment lineup. This may be in the front or back of house, or both. “When possible, we display breads, particularly rolls and loaves, above the front counters,” Jacobs says. “Display deli cases showcasing fresh ingredients can also be a strong focal point.”

Storage for cold containers and lids; insulated foil wrappers for sandwiches; meal boxes with lids; sheets for wrapping; and cello bags for pickles may also be on the line. Along with storage for knives and other utensils, the design should take waste into account.

“Where there’s not a direct back-of-house connection, we often design function-specific, fully enclosed carts for trash receptacles, soiled pans, etc., which can cross through the front of house without being noticed,” Jacobs says.

In looking at how technology has changed the face of make stations, high-speed ovens and induction units have expanded capabilities for hot offerings. “High-speed ovens are fast in heating or finishing hot sandwiches,” Schwartz says. “Even staff with limited skills can take prebuilt sandwiches held cold and quickly heat these up in these ovens.”

With more fluid designs, sandwich make stations can be more versatile to prepare other items, like burgers and salads. “It depends on the station and how it’s supporting the menu,” Schwartz says. “Because many of the same ingredients are used, these lines can provide support for other aspects of the menu. It comes down to the offerings and if there is economy of scale for labor at this station.”