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Gate-to-Galley Engineering for Turnkey Flight Kitchens
Airline & Flight Catering Projects – Engineered in Turkey for Sky-High Efficiency
It ain’t just about reheating meals on board — we learned that the hard way working with catering contractors at regional airports in Turkey and North Africa. One missed tray, one mislabelled pack, and it can mess up service for an entire aircraft. From Istanbul to Kigali, we’ve been inside flight kitchens that serve 500 to 25,000 meals a day. The truth is, you don’t need a massive facility. You need precision. And that’s what Turkey-made flight kitchens offer when designed right.
As a turnkey manufacturer working with kitchen consultants, aviation procurement teams, and facility managers, we offer fully integrated airline catering kitchen setups — ready to handle complex workflows like hot meal prep, cold tray packing, blast chilling, and gate-dispatch sync. Built in Turkey, delivered worldwide. It’s not just kitchen supply. It’s catering logistics engineering.
Shift-Timed Production – 24/7 Meal Prep Aligned to Flight Schedules
✈️ Flight catering is not about cooking — it’s about timing. Our Turkey-built airline kitchens are engineered for:
- Meal prep mapped to flight departure blocks (H-4 to H+2)
- Three-shift continuous operation
- Meal line organization: Hot line, Cold line, Dessert line
- Cross-contamination control by zone + shift
Every production plan is engineered to match your flight schedule. From Qatar Airways’ 03:30 departures to domestic rotations at Lagos Airport, our modular workflow lines adapt to airline load.
Equipment Zones – Modular Units for IATA-Compliant Food Service
We don’t just sell equipment — we structure operations. Here’s what our equipment layouts deliver:
- 700/900 cooking lines with CE certification
- Portioning counters compatible with GN 1/1 trays
- Automated sealing and wrap stations
- Tray trolley paths with timed routing
We also integrate tray packing conveyors with timed push stations, allowing seamless flow from sealing units to trolley loading. Whether you run single-class or multi-class service lines, these conveyors reduce manpower and sync with dispatch timing.
Whether you’re serving business class meals or economy tray sets, our layouts prevent bottlenecks. And every item is manufactured in Turkey with export documents and CE tags ready.
Cold Chain Integration – Blast Chill to Gate in One Flow
Flight meals spend more time waiting than cooking. That’s why cold chain management is critical:
- Blast chillers sized per tray volume (ex: 3000 trays/hr) 📌 Note: Size is calculated based on average flight load + service class differentiation.
- Holding rooms with dual temp zones (4°C / -2°C)
- Tray buffer lanes based on flight dispatch time 📌 Note: Pre-buffering zones reduce last-minute errors before gate loading.
- Dry ice and gel pack loading docks
We build these flows directly into your layout. No retrofits. No temporary hacks. Engineered cold chain.
Gate-to-Galley Synchronization – Real-Time Catering Logic
Flight meal service is a race against boarding time. That’s why we include:
- Flight countdown monitors in tray dispatch areas
- Gate reassignment sync to kitchen alerts 📌 Note: Real-time API integration avoids misrouted trays during last-minute gate changes.
- SCADA or touch-panel monitoring systems
- Delay triggers that update prep schedules 📌 Note: Kitchen receives live delay updates and adjusts batch timers automatically.
Our Istanbul setups currently serve 12,000+ trays/day across 4 airlines. Not a single delayed gate due to kitchen issues — because timing was engineered into the layout.
The Role of Kitchens in Hotel Revenue Strategy
Airline & Flight Catering Projects – Engineered in Turkey for Sky-High Efficiency
📐 Layout & Aviation Compliance – Ready for Audit Day
📋 You don’t want to scramble 2 days before IATA audit. Our layout compliance features:
- Dirty/Clean flow separation for trays and carts
- Drainage slopes for wash zones
- Documented ISO 22000, HACCP, and CE conformity
- Staff hygiene protocols: boot-wash, hand scan, locker zones
- Fire exits, pressurized air, and odor control
Built not just to pass audit — but to make inspectors smile.
📦 OS&E, Packaging & Aviation Consumables – Everything Included
We offer complete kits for:
- Aviation trays (meal class variants)
- Tray sealers (manual, semi, auto)
- Wrapping film, labels, portion containers 📌 Note: All consumables are food-grade and IATA-compliant, supplied in export-ready kits.
- Airline-standard cutlery, napkins, condiments
- GN containers, blast chiller trays, rack trolleys
All OS&E is mapped into the layout. Tagged, labeled, and QR-linked to your BOQ.
📊 Technical Table – Sample Capacity & Flow Data
Component | Specs |
Blast Chiller | 2000 trays/hr (modular) |
Cold Holding | Dual-zone, 4°C/-2°C |
Tray Sealer | Auto sealers, 6 trays/min |
Cooking Line | 900 series, GN 1/1 ready |
Trolley Handling | 150 units per shift |
📩 Contact us for full specs PDF or project proposal.
🌍 Real-World Installations – Airline Kitchens Across Continents
- EgyptAir Cairo Hub – 20,000 meals/day
- 🥗 Qatar Executive Lounge Doha – 3,000 trays/day
- 🥘 UN WFP Flight Base Entebbe – mobile container unit
- 🍜 Turkish Airlines Lounge Istanbul – hot & cold dish prep
Each setup is Turkey-manufactured, site-integrated, and audit-passed.
🧼 Hygiene & Safety – Meet IATA & WHO Standards
Every Turkey-built flight kitchen includes:
- Staff hygiene entry tunnels
- Anti-drip, washable wall panels
- HACCP-ready zones for hot/cold packing
- Fire-rated insulation
- Odor and airflow filtration
We also supply trolley washers and airline-spec dishwashers — designed for deep cleaning of flight carts, trays, and utensils. All washers are CE-certified and include HACCP-compliant drying zones.
Built-in hygiene logic. So you don’t need daily firefighting.
📋 Layout Planning Guide – Choose the Right Design
- Under 5,000 trays/day: linear flow, 2 blast chillers
📌 Note: Ideal for small regional hubs with single airline contracts. - 5,000–15,000: U-shape with dual dispatch zones
📌 Note: Balances prep and packaging flow — optimal for mid-size hubs. - 15,000+: segmented zones, SCADA-controlled
📌 Note: Ideal for hubs handling multiple airlines or meal classes with separate workflows. - Mobile container units: modular add-on paths
📌 Note: Perfect for NGO or relief flight bases.
We design with your tray count, not guesswork.
FAQ – Airline Catering Projects
Can your tray packing lines be synchronized with airline ERP or dispatch software?
Absolutely. We offer SCADA and REST API integrations that allow dispatch sync, tray monitoring, and even auto-update when gate numbers change.
How do you handle allergen separation during high-volume packing?
🅐 We create isolated allergen zones with dedicated portioning tools, color-coded trolleys, and timestamped prep logs to pass international allergen audits.
Can one conveyor system handle both hot and cold meals?
Not ideally. We recommend dual-line systems: one for ambient/cold meals and another thermally shielded line for hot meals to maintain HACCP compliance.
Do you provide airline trolley washers?
Yes. We supply tunnel dishwashers with airline trolley modules, capable of cleaning up to 150 carts/hour with thermal disinfection.
💬 Real Projects & Client Testimonials – What Our Partners Say
