- Aircraft: 12 B747
- Flights per week per aircraft: 4
- Passengers per flight: 400
- Meals per passenger: 3
Total meals per week = 12 × 4 × 400 × 3
= 12 × 4 × 1,200
= 57,600 meals per week
Facility Expansion Overview
To increase capacity from 9,600 to 57,600 meals weekly (6× original), the facility and staffing must scale accordingly.
1. Facility Size & Zones (Approximate)
| Zone | Original Size (m²) | Expanded Size (m²) | Notes |
| Receiving & Dock Area | 120 | 400 | More bays for simultaneous unloading |
| Cold Storage Rooms | 200 | 1,200 | Large walk-in chillers/freezers, separate allergen zones |
| Dry Storage | 100 | 500 | Increased shelving for bulk dry goods |
| Preparation Zones | 250 | 1,500 | Multiple allergen-safe prep stations |
| Cooking Area | 200 | 1,200 | More ovens, rotisseries, steamers |
| Meal Assembly & Packaging | 200 | 1,500 | Multiple assembly lines, conveyor belts |
| Quality Control & R&D Lab | 50 | 100 | Larger test kitchen, expanded tasting rooms |
| Waste Management | 40 | 200 | Scaled for high volume composting & recycling |
| Staff Facilities | 40 | 200 | Expanded locker rooms, restrooms, break areas |
| Office & Admin | 60 | 300 | More admin and coordination space |
| Loading & Dispatch | 80 | 400 | Multiple refrigerated staging bays |
Total expanded facility size: ~7,000 m²
2. Equipment & Infrastructure Scaling
- Cold storage: Large modular walk-in units; temperature zoned
- Cooking equipment:
- At least 6× more ovens, rotisserie ovens, steamers
- Increased sous-vide capacity and blast chillers
- Assembly lines: Multiple parallel conveyor lines, automated packaging/sealing machinery with increased throughput
- Loading docks: Larger and multiple refrigerated docks to handle volume
- IT & quality control: Advanced inventory and production management systems to handle complex scheduling and compliance
3. Staffing Expansion
| Role | Original Staff | Expanded Staff | Notes |
| Executive Chef & R&D Team | 5 | 15 | More menu development teams |
| Kitchen & Prep Staff | 25 | 150 | Larger prep and cooking teams |
| Packaging & Dispatch Staff | 25 | 150 | More packagers, logistics workers |
| Quality Assurance | 5 | 15 | Increased QC and food safety staff |
| Administration & Logistics | 7 | 30 | Additional procurement, scheduling, coordination |
Total staff: ~360 personnel (full shifts)
4. Workflow Adaptations
- Staggered shifts for continuous 24/7 operation if needed
- Specialized allergen and dietary prep stations to minimize cross-contamination at scale
- Robust supply chain management with multiple delivery windows from Cape Town and local Canary suppliers
- Scalable waste processing with automated segregation and composting systems
5. Additional Considerations
- Facility design should allow modular expansion, with structural provisions for vertical or horizontal growth
- Incorporate smart building systems for energy efficiency and environmental controls
- Partnerships with local and international suppliers for just-in-time delivery
Summary
| Parameter | Original Facility | Expanded Facility (12 aircraft × 4 weekly) |
| Weekly meals | 9,600 | 57,600 |
| Facility size | ~1,000 m² | ~7,000 m² |
| Cold storage | 200 m² | 1,200 m² |
| Cooking area | 200 m² | 1,200 m² |
| Staff | ~60 | ~360 |
| Loading docks | 1–2 bays | 6–8 bays |