System and method for assembling trays and food on trays

Abstract

A method and layout for loading food and beverages onto a plurality of trays. The method includes, for each tray in the plurality of trays, performing tray-loading method that includes the steps of selecting a tray from the plurality of trays; and loading the tray with food and beverages, to form an individual, customized tray. Each step in the tray loading method is performed at a different station in a plurality of stations. A path of travel extends alongside the plurality of stations. The first step in the tray-loading method is executed at a starting point in the plurality of stations. The path of travel includes a starting point adjoining the first station. The last step in the tray-loading method is executed at a last station in the plurality of stations. The path of travel includes an end point adjoining the last station. The end point and the starting point in the path of travel are adjacent such that an operator can quickly move from performing the last step of the tray-loading method on a tray at the last station to perform in the first step of the tray-loading method on the next tray at the first station.

1 . A tray assembly system for loading food and beverages onto a plurality of trays, the system comprising: 
 a plurality of stations for performing, for each tray in the plurality of trays, a tray-loading method including the steps of: 
 selecting a tray from the plurality of trays; and,  
 loading the tray with required food, condiments, wares, cutlery and beverages to form a customized tray,  
   the plurality of stations including a first station for performing a first step in the tray-loading method and a last station for performing a last step in the tray-loading method; and    a path of travel for an operator to follow to reach each station in the plurality of stations, wherein the path of travel extends alongside the plurality of stations, and includes a starting point adjoining the first station and an end point adjoining the last station;    wherein the starting point and the end point are adjacent such that an operator can quickly move from performing the last step of the tray-loading method on a tray at the last station to performing the first step of the tray-loading method on the next tray at the first station.    
     
     
         2 . The system as defined in  claim 1  wherein the system includes first, second and third sections, providing the plurality of stations, the first section is substantially parallel to the third section, and the second section extends from the first section to the third section; and, 
 the path of travel extends from the first section through the second section to the third section.  
 
     
     
         3 . The system as defined in  claim 2  wherein 
 the first section has an associated first end and an associated second end,  
 the third section has an associated first end and an associated second end,  
 the second section extends between the associated second ends of the first and third sections;  
 the first station is at the associated first end of the first section; and,  
 the last station is at the associated first end of the third section.  
 
     
     
         4 . The system as defined in  claim 3  wherein the spacing between the first section and the third section is in the range 0.7 meters to 1.5 meters.  
     
     
         5 . The system as defined in  claim 3  wherein the spacing between the first station is a tray station for providing a plurality of trays and the last station is a cart-loading station for loading the plurality of trays onto the cart such that after loading a tray onto the cart at the cart-loading station, the operator can turn around to take the next tray from the tray station.  
     
     
         6 . The system as defined in  claim 5  wherein the plurality of stations includes 
 at least one ware station for providing at least one ware to be loaded on each tray in the plurality of trays, and  
 at least one food station for providing food to be loaded in the at least one ware on each tray in the plurality of trays.  
 
     
     
         7 . The system as defined in  claim 6  wherein each ware station is movably mounted for removal from the plurality of stations and for replacement with a new ware station such that the ware station is removable and replaceable when empty.  
     
     
         8 . The system as defined in  claim 7  wherein 
 the plurality of stations have an inner side facing the path of travel, and an outer side facing away from the path of travel; and  
 at least one ware station is removable and replaceable from the outer side to avoid obstruction of the path of travel.  
 
     
     
         9 . The system as defined in  claim 8  wherein the first station and the last station are on different sides of the path of travel such that after performing the last step in the tray-loading method on a tray at the last station, the operator can turn around to perform the first step in the tray-loading method on the next tray at the first station.  
     
     
         10 . The system as claimed in  claim 9 , which includes a counter, for sliding movement of trays, extending along the path of travel from the first station to the last station.  
     
     
         11 . The system as claimed in  claim 10 , which includes at the start end, a condiment section for dispensing condiments, and providing space to accommodate at least one movable cart for trays.  
     
     
         12 . The system as claimed in  claim 11 , wherein the condiment section includes space to accommodate a movable cart for trays and a movable cart for dividers.  
     
     
         13 . The system as claimed in  claim 12 , wherein the first section includes shelving for presenting at least one of dessert items and bakery items, and includes a bottom part for storing beverages.  
     
     
         14 . The system as claimed in  claim 13 , wherein the bottom part of the first section is refrigerated and wherein the counter includes a straight part extending across the front of the first section and including open grates, permitting access to the bottom part.  
     
     
         15 . The system as claimed in  claim 14 , wherein the second section includes a refrigerated bottom part, for holding soup containers, and wherein between the first and second sections, at the rear of the counter, space is provided for a wheeled cart for holding soup bowls.  
     
     
         16 . The system as claimed in  claim 15 , wherein the third section comprises an entrée section having a refrigerated base and providing a plurality of containers for holding entrée items, and wherein, between the second and third sections, there is provided a space at the rear of the counter, for a wheeled cart for holding wares for entrées.  
     
     
         17 . The system as claimed in  claim 16 , including a beverage dispenser provided adjacent the third section and a space for a movable cart for covers for wares, for providing each tray with any required beverage and covers for filled wares.  
     
     
         18 . The system as claimed in  claim 7 , wherein each ware station includes a lowerator for a stack of wares, for maintaining an uppermost ware of the stack at a substantially constant height.  
     
     
         19 . The system as claimed in  claim 16 , wherein at least one of the second and third section includes a movable cover for covering and protecting food, during breaks in operation.  
     
     
         20 . A tray assembly system for loading food and beverages onto a plurality of trays, the system comprising: 
 a plurality of stations for performing, for each tray in the plurality of trays, a tri-loading method including the steps of: 
 selecting a tray from the plurality of trays; and  
 loading the tray with required food, condiments, wares, cutlery, beverages, to form a customized tray, the plurality of stations including a first station for performing a first step in the tray-loading method and a last station for performing the last step in the tray-loading method;  
   a path of travel for an operator to follow to reach each station in the plurality of stations, wherein the path of travel extends along one side of the plurality of stations, and includes a starting point adjacent the first station and an end point adjacent the last station;    wherein the system includes a plurality of carts for wares, each cart being located at one of the other side of the stations and adjacent one of the first and last stations, whereby each cart can be removed and replaced without crossing the path of travel, whereby, in use, each cart can be replaced to replenish the supply of wares without interrupting an operator.    
     
     
         21 . A station, for use in assembling trayed food, the station comprising: 
 a framework defining a bottom compartment for storing food products;    along at least the front of the station, at least one grate providing a surface for supporting a tray and for providing openings for access to the bottom compartment, to enable an operator to reach through the grate to select food items from the bottom compartment.    
     
     
         22 . The system as claimed in  claim 21 , wherein the bottom compartment includes lowerators for supporting containers for food items, and wherein hinge grates are provided, for providing access to the bottom compartment to replace the food containers.  
     
     
         23 . The system as claimed in  claim 22 , wherein the station includes shelving above the bottom compartment for presenting additional food items for selection, and a refrigeration system for circulating chilled air through the bottom compartment and over the shelves, the air returning through the grates.  
     
     
         24 . A tray assembly method for loading food and beverages onto a plurality of trays, the method comprising, for each tray in the plurality of trays, performing a tray-loading method including the steps of 
 selecting a tray from the plurality of trays, and    loading the tray with required food, condiments, wares, cutlery and beverages to form a customized tray; wherein 
 each step in the tray-loading method is performed at a different station in a plurality of stations,  
 a path of travel extends alongside the plurality of stations;  
 the first step in the tray-loading method is executed at a first station in the plurality of stations;  
 the path of travel includes a starting point adjoining the first station;  
 the last step in the tray-loading method is executed at a last station in the plurality of stations;  
 the path of travel includes an end point adjoining the last station; and,  
 the end point and the starting point are adjacent such that an operator can quickly move from performing the last step of the tray-loading method on a tray at the last station to performing the first step of the tray-loading method on the next tray at the first station.  
   
     
     
         25 . The method as defined in  claim 24  wherein each step in the tray-loading method is performed by a single operator.  
     
     
         26 . The method as defined in  claim 25  wherein 
 the first step in the tray-loading method comprises selecting a tray from a tray station; and  
 the last step in the tray-loading method comprises loading the tray onto a cart,  
 such that after loading a tray onto the cart at the cart-loading station, the operator can turn around to take the next tray from the tray station.  
 
     
     
         27 . The method as defined in  claim 26  wherein 
 the plurality of stations includes 
 a ware station for providing at least one ware to be loaded on each tray in the plurality of trays, and  
 a food station for providing food to be loaded in the at least one ware on each tray in the plurality of trays; and,  
 
 the tray-loading method further includes the step of loading the at least one ware onto the tray.  
 
     
     
         28 . The method as defined in  claim 27  further comprising, when the ware station is empty, replacing the ware station with a new ware station, wherein the ware station is movably mounted for removal from the plurality of stations and for replacement with the new ware station.  
     
     
         29 . The method as defined in  claim 28  wherein 
 the plurality of stations have an inner side facing the path of travel, and an outer side facing away from the path of travel; and  
 the ware station is removable and replaceable from the outer side to avoid obstruction of the path of travel.