Food trucks may include different equipment, but the design protocol remains the same across the board.

Traditional restaurant kitchens and food trucks share one common goal: to maximize efficiency and accessibility with a smooth flow. With food truck design, it’s about minimizing steps and staff not running into each other, says Matthew Anderson, associate principal, Rippe Associates, Minneapolis. 

Along with that smooth flow, the design must also situate the equipment around interior wheel fenders, which can be pretty tricky. In trucks with a triple axel, for example, the wheel fender takes up about 91 inches of space where designers can’t place solid appliances, notes Keith Brown, sales director at Concession Nation. “We’ve designed more than 4,000 trailers, and in my opinion, working with brick-and-mortar restaurants is easier,” he says. “Trucks have the same concept, but it’s difficult to create the ideal setup.”

Although food truck lengths can range from 10 to 25 feet, with widths averaging 7 to 8 feet, equipment tends to be identical to a traditional kitchen. Despite the limited space and additional challenges with power sources, Victor Pelayo, owner, Worldwide Design Concepts, La Mirada, Calif., says that he approaches food truck design the same as traditional kitchen design.

A second similarity: Menu and service type dictate key decisions that impact equipment purchases and workflow in the space. “It’s critical to understand the core menu items in order to select appropriate equipment as well as how the service will be executed within the truck,” Anderson explains. “If there is a service counter, how does that person interact in the space with someone who might be cooking? If it’s self-order with a tablet or via a smartphone, that changes how we might think about the layout.”

Other factors include ingredient storage, cooking, and space for packaging and presentation. Future iterations of the food truck menu also come into play as offerings tend to be more fluid than brick-and-mortar operations. “With a food truck, as with traditional kitchens, there is no such thing as a standard equipment lineup,” Pelayo says. “And it’s more important than ever to make use of every inch.”

As in traditional kitchens, the least amount of both staff movement and crossover plays a crucial role in any successful design. “Being aware of how the team works together in the space, how menu items will be cooked, and then how the final presentation is assembled for the consumer are key elements that should be looked at early on in the design process,” Anderson notes.

Equipment logistics are an aspect that looks different in the limited space of food trucks compared with brick-and-mortar foodservice operations. “For example, fryers will have the guts in front so the back can be situated on the truck’s wheel fender,” Brown says. “Or in the case of equipment generating a lot of heat, like charbroilers or slushy machines, placement is a big factor due to safety concerns.”

The design should also take into account beverage needs. “Food truck operators may be accommodating for beverages with a stand-up or undercounter reach-in refrigerator,” Anderson says. “Other considerations are restocking or prep for the next day for instances when the food truck is staying put for multiple days.”

Another distinguishing factor with food trucks is the sink situation. Although prep sinks make sense in restaurants, they may not be necessary or even feasible in food trucks. “The major difference is the amount of sinks,” Pelayo says. “Food trucks typically only have space for a three-compartment sink and a hand sink since much of the prep is accomplished in a commissary or off-site kitchen.” 

By code, sinks should be large enough to submerge the truck’s largest utensil. The design also must consider local requirements, which vary. For example, California requires 32 linear feet of storage in commercial kitchens.

Also in California, the code is 216 square inches for a self-closing window or 432 square inches with an air curtain. South Carolina is 24 inches by 24 inches for a self-closing window. Brown notes the codes seem to be constantly changing.

Also consider the length and weight distribution when placing equipment in a food truck. “Sometimes even heavy-duty trucks can lean to the left or right, and lean springs will be required,” Brown says. “If there is too much weight in the front of the trailer, the tow weight increases, and a high-powered truck is required for transport.” This will also impact travel speed as the vehicle won’t be able go as fast.

Other key factors when conducting weight calculations include refrigerator contents, sinks with heavy freshwater tanks and weighty propane tanks to support cooking equipment. “When considering the truck’s length, there shouldn’t be too much equipment piled in,” Brown says. “The truck’s front should be kept as light as possible, with heavier equipment in the center.” Tow weight is 10% of the gross vehicle weight (GVW), which is the maximum amount of weight a trailer can carry.

In addition, the proper towing vehicle is necessary or the trailer will dip and sway during transport. “Anti-sway bars can help a little bit, but we can’t rely on them,” Brown explains.

Utility accommodations are another primary factor to consider in food truck design. “Trucks may have to be reconfigured to handle electrical loads, and space has to be allocated for a generator,” Anderson says. 

Brown formerly worked on one food trailer that had three air-conditioning units, so a split AC or duct system was created. “Without proper AC and ventilation, with fryers and burners emitting constant heat, interior food truck temperatures can go up to as much as 120 degrees,” Brown says. 

As part of the utilities, all food trucks include a plumbing system, and requirements for these are the same in all states. “This involves both fresh and gray water tanks,” Brown says. 

In addition to mandatory propane systems, designs must factor in gas lines, shutoff valves, ventilation hood systems and fire suppression systems. “Shields are needed to protect lighting, and everything has to be of food code,” Brown says. 

How a team works in a food truck space is critical to designing for the truck’s tight quarters. Photo courtesy of Concession Nation

Critical Components and Layouts

Food trucks should be configured with everything moving in one direction, rather than back and forth, within the space. “Once product is loaded in and parked, all things should flow effortlessly in a single direction,” Anderson says. “Minimalistic is best, and not only is it important that proper equipment is specified but also to be mindful of storage space and how items are stocked.”

The design is not just about equipment placement but also using the truck’s height to the best possible advantage. “It’s important to think about going up and down, not just left to right,” Anderson notes. “This is an opportunity to look at kitchens differently because maximizing square footage is so important.”

Whether it needs a grill, smoker or fryer, a food truck can accommodate a variety of equipment. “Everything runs on propane or electricity,” Pelayo says. “The design can incorporate a tankless water heater or ductless mini split heat pumps, depending on the budget.”

A typical food truck has an ordering window on the right and a pickup window on the left or a single window for both transactions. “Inside, there would be a cashier and service counter inside the right window, and likely that person is both taking orders and preparing vessels for assembly,” Anderson says. “There would be a cook facing opposite the guest in the left window.” 

This setup minimizes employee crossover and allows the cook to assemble the final dish, turn around and present orders in the pickup window. “The design could allow for a single person to execute inside the space, if need be,” Anderson says. “It’s important not to place equipment across the truck so employees don’t have to step outside the circle.”

Like in a traditional kitchen, keeping everything within arm’s reach is the goal. As for the equipment lineup, the food truck’s size will determine the type of units that can be accommodated. “For a 20-foot truck, we would have a 24- or 36-inch broiler and a 2- to 5-foot griddle, plus a couple hot plates or up to four if stock pots will be used,” Pelayo says. “Designs also typically include a prep table for sandwich production and a 24- to 48-inch hot food table.”

In addition to three-compartment and hand sinks, other common equipment includes a reach-in refrigerator and reach-in freezer, a soda fountain and at least 6 feet of counter, depending on the truck length. Heat lamps should be specified for holding areas, and overhead or undercounter storage will need to be carved out. “Operators are only packing what they need for the day,” Pelayo notes. “And most everything is coming out of refrigeration and being cooked.” 

Equipment Innovations

Though space constraints are a common denominator in all commercial kitchens, food trucks take them to a whole new level.

“That’s why I look for multifunctional equipment such as ovens that can cook, steam and microwave,” Pelayo says. “The most you can pump out of a space with the least amount of equipment, the better.”

In addition, Pelayo is a big proponent of sous vide, where food is prepared in a commissary, then refrigerated and reconstituted in the food truck. Brown is increasingly seeing equipment like steamers and tilt skillets incorporated into food trucks as well as rethermalization equipment for reheating purposes. “Newer brewing systems also can offer multiple types of coffee products in the same space,” Pelayo says. 

Equipment that’s simple to operate for one person, like combi ovens, clamshell grills and fryers, makes it easier for limited staff to multitask without the risk of product waste from overcooking or undercooking. “The design should incorporate equipment that supports staff like auto basket raising for fryers,” Anderson says. “These automation features keep getting better and better, making food trucks more versatile.”

Another time-saver is utilizing stainless-steel surfaces inside the truck, which makes it easy to pressure wash or mop without damaging equipment. “The designer should be mindful about how someone can be functional in that space, make sure each piece of equipment is being used and see what can serve double duty,” Anderson notes.