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Operations Capacity

Reeshemah Culler

South University

MGT3059 – Operations Management SU01

Prof. Patrick Udeh

13th May, 2024

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Steps/Equipment

Here are the typical steps and equipment required for producing doughnuts:

1. Mixing Ingredients

 Steps: Combine flour, sugar, yeast, salt, eggs, butter/oil, and other ingredients in the

specified proportions. Mix until a dough forms.

 Equipment: Large mixing bowl, stand mixer or hand mixer, measuring cups/spoons.

2. Kneading

 Steps: Knead the dough by hand or using a dough hook attachment to develop gluten

structure.

 Equipment: Clean surface for kneading or stand mixer with dough hook.

3. Proofing/Rising

 Steps: Place the kneaded dough in a greased bowl, cover, and let it rise for the

specified time in a warm environment.

 Equipment: Greased bowl, damp cloth or plastic wrap to cover.

4. Rolling and Cutting

 Steps: Roll out the risen dough to the desired thickness using a rolling pin. Cut into

doughnut shapes using doughnut cutters or biscuit cutters.

 Equipment: Rolling pin, doughnut/biscuit cutters, clean surface for rolling.

5. Proofing/Resting (Optional)

 Steps: Let the cut doughnuts rest and rise again for a short time before frying.

 Equipment: Baking sheets lined with parchment paper or lightly greased.

6. Frying

 Steps: Fry the doughnuts in hot oil (350-375°F) until golden brown, flipping halfway

through.
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 Equipment: Deep fryer or heavy-bottomed pot for frying, slotted spoon or tongs for

turning.

7. Glazing/Decorating (Optional)

 Steps: While still warm, dip or drizzle the fried doughnuts in glaze, frosting, or

desired toppings.

 Equipment: Bowls for glazes/toppings, dipping tools or piping bags.

8. Cooling and Serving

 Steps: Allow the glazed/decorated doughnuts to cool slightly before serving.

 Equipment: Wire racks or parchment paper for cooling.

Note: Additional equipment like bowls, whisks, spatulas, and baking sheets may also be

required depending on the specific doughnut recipe and production process.

Bill of Material

Here is a typical bill of materials for the ingredients required to produce doughnuts:

Dry Ingredients:

o All-purpose flour

o Granulated sugar

o Brown sugar (optional)

o Baking powder

o Salt

o Ground cinnamon (optional)

o Ground nutmeg (optional)

Wet Ingredients:

o Milk

o Eggs

o Unsalted butter or vegetable oil

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o Vanilla extract

Yeast:

o Active dry yeast or instant yeast

For Frying:

o Vegetable oil, shortening or lard for frying

Glazes/Toppings (Optional):

o Powdered sugar for glazing

o Milk or water for thinning glaze

o Sprinkles

o Chocolate/Vanilla glaze

o Cinnamon-sugar mixture

The specific quantities of each ingredient will depend on the recipe being used and the

desired batch size. Additionally, some recipes may call for additional ingredients like mashed

potatoes, sour cream, or buttermilk for a richer dough.

Capacity of the Doughnuts Production Operation

The maximum capacity or number of doughnuts that could be produced per hour

would primarily depend on the equipment capacity, available labor, space and layout, as well

as the specific recipe and production process employed.

The size and capacity of the deep fryer or frying setup will determine how many

doughnuts can be fried simultaneously. Similarly, the size of the mixer and other equipment

will impact the batch sizes that can be prepared at once. The number of employees dedicated

to the production line and their efficiency in executing each step, such as mixing, rolling,

cutting, frying, and glazing, also plays a crucial role. Having multiple workstations or an

assembly line setup can significantly increase the overall throughput (Doughnut Production

Facility, 2021).
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The available workspace and the layout of the production area are equally important

factors. An efficient layout allowing for a smooth flow between stations, along with adequate

space for proofing/rising doughnuts and cooling racks, can streamline the process. The

specific doughnut recipe and the time required for steps like proofing, frying, and cooling can

also impact the maximum capacity (Singh et al., 2019).

Assuming a small doughnut shop with a few employees, a standard deep fryer, and a

basic production setup, a reasonable maximum capacity could be producing and frying 2-3

dozen doughnuts every 15-20 minutes. This could translate to approximately 6-12 dozen

doughnuts per hour, or 72-144 doughnuts per hour. However, this is just a rough estimate, and

the actual capacity would depend on factors like the skill level of the staff, the efficiency of

the equipment, and the specific production processes employed. Conducting trial runs and

optimizing the workflow would be necessary to determine the precise maximum capacity for

a given setup.

Increasing Production Capacity

If the doughnut business becomes incredibly successful to the point of selling frozen

doughnuts through grocery stores nationwide, increasing the production capacity and

changing the process strategy would be necessary. This could be achieved through the

following measures:

First, transitioning to a larger-scale commercial production facility with industrial-

grade equipment would be essential. This includes investing in high-capacity mixers,

automated dough rollers and cutters, and multiple large-scale fryers or frying lines.

Automated glazing and packaging equipment could also be implemented to streamline the

process (Gisslen, 2017). Additionally, incorporating advanced technologies like computer-

controlled processes and robotic systems could further enhance efficiency and consistency

(Mallet et al., 2019).

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Second, adopting a mass production approach with a continuous flow process would

be crucial. Instead of batch production, a continuous assembly line with dedicated stations for

each step, such as mixing, proofing, cutting, frying, glazing, and packaging, would enable

higher output. This approach would also require a larger workforce and potentially multiple

shifts to maintain continuous operation (Doughnut Production Facility, 2021).

Third, implementing strict quality control measures and adhering to food safety

regulations would be paramount. This includes regular equipment maintenance, sanitization

protocols, temperature monitoring, and rigorous product testing to ensure consistent quality

and food safety across large-scale production (Hui et al., 2007).

Finally, an effective distribution and logistics strategy would be required to transport

the frozen doughnuts to grocery stores nationwide while maintaining product quality and

freshness. This may involve investing in a fleet of refrigerated trucks, establishing a network

of distribution centers, and implementing sophisticated inventory management systems

(Doughnut Production Facility, 2021).

Conclusion

Establishing a successful doughnut business requires careful planning and

consideration of the production process, whether starting small or aiming for large-scale

nationwide distribution. A small hometown operation involves understanding the step-by-step

process, obtaining necessary equipment, and managing capacity based on factors like labor

and workspace. However, expanding to sell frozen doughnuts in grocery stores nationwide

necessitates transitioning to a commercial facility with industrial equipment, adopting mass

production with continuous flow processes, implementing stringent quality control, and

establishing an effective distribution network. Regardless of scale, attention to detail, food

safety compliance, and consistently producing high-quality doughnuts are essential for

satisfying customer cravings and achieving success in the doughnut business.

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References

Doughnut Production Facility. (2021). Doughnut production line setup and optimization.

Bakery Equipment Manufacturers Association.

Doughnut Production Facility. (2021). Large-scale doughnut production and distribution.

Bakery Equipment Manufacturers Association.

Gisslen, W. (2017). Professional baking (7th ed.). John Wiley & Sons.

Hui, Y. H., Bruinsma, B. L., Gorham, J. R., Nip, W. K., Tong, P. S., & Ventresca, P. (2007).

Food plant sanitation. CRC Press.

Mallet, S., Melrose, J., & Cirino, J. (2019). Automation and robotics in the food industry:

Current and future trends. In M. L. Cirino (Ed.), Robotics in the Food Industry (pp. 1-

25). Woodhead Publishing.

References:

Singh, J., Singh, A. P., & Raghav, P. K. (2019). Doughnut production: A review. International

Journal of Food Science and Nutrition, 4(2), 120-124.