In Dubai, Emirates flight catering makes 110 million
in-flight meals a year. As the world’s largest catering facility, they run 24/7
cooking up every snack, dessert and main dish eaten by the airline’s 55 million
passenger a year. And these travelers eat a lot.
In 2018, Emirates passengers downed 72 million bread rolls,
over 134,000 pounds of strawberries, 414 pounds of salmon, and more than three
million pounds of potatoes. So how does the world’s largest flying restaurant
feed hungry passengers abroad nearly 200,000 flights a years?
Well before any cooking is done everything has to be
unloaded off incoming flights. The plates and trolleys are dropped in the
ground floor of the facility to be cleaned. Dishes are separated into categories
and sent through industrial-sized ware washing machines. On average the
facility handles about 3 million pieces of tableware a day. Those trolleys that
bring you drinks during your flight are also cleaned which are then loaded up
to the mile and a half long monorail to be taken upstairs.
This system is how massive amounts of inventory are moved
safely through the building. The monorail has pick up and drop off points at
multiple locations at every floor. Upstairs is where the cooking takes off.
First in the cold kitchen, all of the sandwiches and appetizers are prepped and
plated. Because the different cabins have specific menus, appetizers and
sandwiches for first and business class are prepared on one side of the
kitchen. While those for the economy is prepared on the other. Sandwiches are
sliced and stacked and then feed through. Sandwiches are sliced and stacked
then feed through the flow wrapping machine to keep the bread fresh until it’s
unwrapped aboard the plane. The kitchen is broken down by four food regions:
Asian, Sub-Continent, European and Middle Eastern. Emirates 1800 chefs from
around the world develop 1300 different menus a month. They cover the culinary
gambit of every destination Emirates flies to. Whenever you are aboard an
Emirates flight the meal you are served is inspired by the region of your
arrival destination with over 150 destinations in 85 different countries.
They use a hydro processor, a high powered water laser that
cuts perfectly precise slices of cake. Finally, the assembly room where it is
all assembled and converted to one tray. It is in here that each package gets a
UV ink on it which is invisible by the passenger. But the ink helps the
Emirates to track the life of each dish which helps them to prevent themselves
from serving the spoilt dishes to the travelers. It’s the same place where the
salads are packed. The dishes are assembled and loaded into the trolleys
exactly how a passenger sees it. These trolleys are carried by the monorails to
the downstairs where the trolleys are transferred to trucks which will be sent
to the aircrafts in next two hours to serve the hungry passengers waiting
aboard.
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