Emirates Flight Catering: 38 million meals a year

Summary

Emirates Flight Catering in Dubai is the world’s largest catering facility, producing 125,000 meals daily for Emirates Airlines. The operation spans a vast array of specialized kitchens, staffed by over 450 chefs from 43 different nationalities, to prepare meals catering to diverse regional tastes. The facility boasts cutting-edge technology, including an automated monorail system for meal transport and industrial car washes for equipment. Strict temperature controls ensure food quality and freshness, with meals prepared, chilled, and dispatched with precision to meet global flight schedules. The entire operation runs 24/7, providing gourmet dining experiences at 35,000 feet.

Takeaways

• 😀 EKFC (Emirates Flight Catering) in Dubai is the world's largest catering facility by volume, preparing over 125,000 meals daily for Emirates Airline.
• 🍴 The facility has the design capacity to produce up to 130,000 meal trays per day, with chefs from 43 different nationalities.
• 🌍 Ingredients are sourced globally, with beef from the US, salmon from Norway, and lamb from Australia, among others.
• 🍳 EKFC utilizes cutting-edge kitchen technology, including saltwater brine systems for chillers, which help maintain optimal food quality.
• 🍲 The kitchen setup includes specialized areas for preparing cold dishes like appetizers and salads, as well as a dedicated bakery for Arabic sweets and desserts.
• 🥗 100 staff members work in the cold kitchen area, preparing items such as Arabic mezze and gold cup plates for business class meals.
• 🍞 The bakery produces a range of items, including chocolate chip muffins, meringues, and cheesecakes, all made in-house.
• 🚉 A state-of-the-art monorail system transports 7,500 meal carts per day, streamlining the logistics and distribution process within the facility.
• 🔄 Over 2 million items, such as cutlery and trays, are cleaned daily through industrial washing systems, ensuring hygiene and operational efficiency.
• 🌡️ Strict temperature control is maintained throughout the facility to ensure food quality and safety, with chilled food kept between 2-3°C to prevent temperature abuse.
• ✈️ EKFC operates 24/7 to ensure timely delivery of fresh meals to Emirates flights, with food items dispatched two hours before departure to maintain freshness.

Q & A

What makes Emirates Flight Catering (EKFC) the largest flight catering facility in the world?

EKFC is the largest in the world based on its volume throughput, with the capacity to prepare up to 130,000 meal trays per day. It serves meals for Emirates Airlines, offering a vast range of over 1,500 different menus.

How many chefs work at EKFC, and what is the significance of their diverse backgrounds?

EKFC employs 450 chefs from 43 different nationalities. This diversity is crucial as it allows the facility to produce a wide variety of regional cuisines, ensuring that every meal aligns with cultural and culinary expectations.

What is the process for meal preparation at EKFC?

The process begins with menu planning, followed by the procurement of ingredients from around the world. Once ingredients arrive, meals are prepped, cooked, chilled, and then plated. Different areas within the facility are dedicated to specialized tasks such as cold dishes, pastries, and regional cuisines.

How does EKFC ensure the freshness and quality of meals?

EKFC maintains strict temperature control throughout the entire process, from food preparation to transportation. Meals are stored in chillers that operate at 2-3°C, and all meals are kept below 8°C during transport to prevent any temperature abuse, ensuring that passengers receive fresh meals.

What types of high-tech equipment are used in EKFC's kitchens?

EKFC uses advanced kitchen solutions such as automated rat pans, ovens, and roasting systems. Their chillers use a saltwater brine system, which is gentler on the food and ensures stable temperature maintenance with less maintenance.

What is the role of the monorail system at EKFC?

The monorail system at EKFC transports meal carts and pallets automatically between the ground floor and the first floor. It also moves airline carts through the warewashing lines, helping the facility manage its operations efficiently.

How does EKFC handle the cleaning and sanitization of meal equipment?

EKFC has a highly efficient warewashing system that handles over 2 million items per day. Meal trays, cutlery, and glassware are washed in industrial machines, which are designed to clean and sanitize at high volumes, ensuring hygiene standards are met.

What are the key components of the high bay store at EKFC?

The high bay store at EKFC is a warehouse that holds a 24-hour supply of stock, including equipment and consumables. It is replenished several times a day to ensure smooth operations and to prevent shortages during the food production process.

How does EKFC ensure that meals meet strict food safety standards during transportation?

Meals are transported in trucks that maintain temperature-controlled environments. All food items are carefully loaded and secured to prevent contamination. Temperature checks ensure that the meals are kept below 8°C before being dispatched to the aircraft.

What types of cuisines are produced at EKFC, and how does the facility cater to different dietary requirements?

EKFC produces meals from a wide range of cuisines, including Arabic, Western, Subcontinental, and Asian dishes. It also accommodates special dietary needs, such as low-calorie, diabetic, and halal meals, ensuring all passengers' preferences and restrictions are met.