Meal assembly at the new Emirates Flight Catering unit in Dubai

Emirates Flight Catering opens new unit

Emirates Flight Catering’s new facility in Dubai, boasting a capacity for up to 115,000 meals per day at an investment of US$120 million became fully operational this month.

The new unit has four floors and is exclusively for the catering of Emirates’ 95 departures per day out of Dubai. The caterer’s other facility will serve its airline customers.

The new HACCP-compliant unit has a number of automated systems. An electronic monorail system moves meal carts and a bin conveyor system handles equipment. Emirates Flight Catering has also installed a vacuum waste disposal system throughout the unit. The caterer’s management team designed much of the unit working with i+O, the well-known German industrial design company that has been called on to help build a number of catering units around the world. The computer module designed by Oracle integrates the standard forecasting, procurement, inventory control and catering order processing.

Meals make their way to the aircraft through the caterer’s fleet of 98 high-loaders. An additional 31 trucks are on order.

For cuisine, Emirates Flight Catering has preparation areas for Chinese, Japanese, Indian, Arabic and Continental meals. EKFC plans a selection of 24 special meals. All meats entering the kitchen are fully halal and no pork or pork products are allowed in the facility.

As Emirates continues its fast track to growth, which includes a massive order for A380s, the caterer will be called on to produce an expected 45 million meals per year by 2014. In the past year, the airline has added three daily flights between New York/Kennedy and Dubai. Later this year routes to Houston and Toronto will be added.

Emirates Flight Catering’s new unit at a glance

Total area

55,000 sq. meters
Total cost US$120 million
Daily Meal Capacity 115,000
Meal and service equipment items processed daily 1.5 million
Monorail cart transport system  2.55 kilometers
Number of carts handled per day 17,000
Number of galley boxes handled per day 13,000
Equipment bin transport conveyor  1.10 km
Number of CCTV cameras throughout the facility 220
Ice cube production 24 tons per day
Source: Emirates