Pizza & Salad Prep Counters: Food‑Safe Rails, Pan Layouts & Energy Math (AU)
Shop related categories: Pizza Prep Fridges · Salad Prep Fridges · Benchtop Salad Bars
1) Compliance: ≤5 °C rails, 2‑hour/4‑hour rule & thermometers
- Keep potentially hazardous food at 5 °C or colder, or 60 °C or hotter. This applies to display/rails as well as storage. See FSANZ guidance “Keeping food at the right temperature”.
- 2‑hour/4‑hour rule: total time between 5–60 °C is cumulative. Under 2 h → use/return to cold; 2–4 h → use or discard; >4 h → discard. FSANZ provides a one‑page explainer and factsheet.
- Thermometer: have at least one accessible probe thermometer accurate to within ±1 °C and use it on the food (not just the dial).
Official references in Section 12 include FSANZ pages for temperature control, the 2‑hour/4‑hour rule and thermometers—all stable URLs.
2) Rails that hold temp: open vs enclosed lids, draught control
Open rails are fast for service but more exposed to warm air; they demand tight probe checks and time‑as‑control logs. Flip‑top or enclosed rails (with sneeze guards or sliding lids) reduce warm air entrainment, cut compressor cycling and make ≤5 °C easier during long services.
| Rail style | Strengths | Watch‑outs | Best for |
|---|---|---|---|
| Open (no lid) | Fast access; full visibility | Warm edges; frequent probe checks; rely on 2‑hour/4‑hour rule | Short, intense peaks with disciplined logging |
| Flip‑top / hinged | Close between orders; stabilises top layer | Staff must close lids; hinges & gaskets need care | All‑day service; smaller teams |
| Enclosed + guard | Best temperature integrity; draught protection | Slightly slower access | Front‑of‑house salad bars; hot kitchens; long holding |
3) GN pan sizes (1/2–1/9) & ingredient mapping
Common GN outer sizes (quick reference)
| GN size | Length × Width (mm) | Typical depths (mm) |
|---|---|---|
| 1/1 | 530 × 325 | 65 / 100 / 150 |
| 1/2 | 325 × 265 | 65 / 100 / 150 |
| 1/3 | 325 × 176 | 65 / 100 |
| 1/6 | 176 × 162 | 65 / 100 |
| 1/9 | 176 × 108 | 65 / 100 / 150 |
Sizes per AU supplier guides (e.g., Nisbets size table; Roband AU steam‑pan sizing).
Map ingredients → pan size & depth
| Ingredient / Prep | Recommended pan | Notes |
|---|---|---|
| Lettuce / slaw (high volume) | 1/2 GN, 100 mm | Busy takeaways typically keep leafy bulk in 1/2 GN to cut top‑ups and keep the chill plane over the product. |
| Proteins (ham, chicken, salami) | 1/3 GN, 65–100 mm | Split high‑risk items into two smaller pans and position in the coldest part of the rail. |
| Wet toppings (olives, pineapple, capsicum, tomato) | 1/6 GN, 65–100 mm | Shallow pans help keep the top layer below the chill line. |
| Garnish / low‑volume (lemon, chilli, herbs) | 1/9 GN, 65–100 mm | Ideal for small items and allergen segregation with dedicated utensils. |
| Base storage (beneath bench) | 1/1 GN trays | Use for backup stock; rotate to the rail in small, cold top‑ups. |
Remember: check the food temperature with a probe—≤5 °C is the standard for display; time‑as‑control is the alternative with records.
4) Optimised layouts (incl. 2100 mm rails) & downloadable grids
Below are realistic, menu‑driven layouts you can adopt today. We’ve highlighted the sizes most venues ask for. Counts are indicative; exact capacity varies by brand and cut‑out.
Quick planner — typical rail capacity by width
| Rail width (approx.) | Common options (across the rail) | Good for |
|---|---|---|
| 1200 mm | 6 × 1/3 • 4 × 1/2 • 8–12 × 1/9* | Compact pizza & café lines |
| 1500 mm | 8 × 1/3 • 5–6 × 1/2 • 12–16 × 1/9* | Mid‑volume pizza/salad |
| 1800 mm | 10 × 1/3 • 6–7 × 1/2 • 16–18 × 1/9* | Busy dinner rush |
| 2100 mm | 8 × 1/2 (busy takeaway favourite) • 10–12 × 1/3 • 18–24 × 1/9* | High‑volume pizza & salad bars |
*1/9 counts assume small garnish wells; always confirm the manufacturer’s rail cut‑out. For 2100 mm benches, many sites run 8 × 1/2 GN across the rail to anchor bulk items (e.g., lettuce, shredded cheese), then deploy 1/3 and 1/9 for proteins and garnishes.
Downloadable 2100 mm rail grids (right‑click → Save image)
5) Climate classes: what “Class 4 (30 °C/55% RH)” means
Professional refrigerated storage cabinets/counters are often tested to EN 16825 at climate class IV—that is, 30 °C ambient / 55% RH. It’s a useful benchmark, but your live line may run hotter (ovens, westerly sun, doorways), so lid discipline and probe checks still matter at the rail.
6) Energy: kWh/24 h → $/year calculator
7) SOPs: probe checks, lid etiquette, gaskets
During service
- Probe the warmest pan top layer on the hour and half‑hour—target ≤5 °C. Log in your food‑safety records.
- Lid etiquette: open to scoop, close to hold. Add a simple sticker as a cue.
- Stir & level pans; keep product below the chill plane; use shallow pans for slow movers.
- If any pan exceeds 5 °C, apply the 2‑hour/4‑hour rule and record the time.
Close‑down
- Move high‑risk proteins from the rail to the base at ≤5 °C overnight.
- Wipe lids; replace split gaskets; clean condenser every 4–6 weeks to protect performance.
- Verify your thermometer accuracy (±1 °C) and clean/sanitise the probe between uses.
8) Editor’s pick: what we look for in AU‑ready prep counters
- Class 4‑ready storage section (30 °C/55% RH test) and lidded rail for long service windows.
- Food‑safe rail geometry: keeps the top of product under the chill plane; clear cut‑out for 1/2 + 1/3 + 1/9 mixes.
- Serviceability: robust, replaceable gaskets; easy‑clean condenser; accessible drain.
- Efficient system: R290 refrigerant, ECM/EC fans, clear kWh/24 h on spec.
Ask our team for current “best buys” in pizza prep and salad prep by size and budget.
9) Case study: Melbourne CBD pizza bar
| Context | Problem | Interventions | Results (90 days) |
|---|---|---|---|
| Small CBD pizzeria; rail beside a 3‑deck oven; open rail stacked deep; no probe logs. | Top‑layer temps 7–8 °C during peak; council requested 3.2.2A evidence. |
|
|
10) FAQ
- What temperature should my prep rail hold?
- Keep potentially hazardous food at ≤5 °C during display. If not achievable at peak, apply the 2‑hour/4‑hour rule with records and corrective actions.
- What GN sizes do busy takeaways use?
- Most run 1/2 GN for leafy bulk (lettuce, slaw), 1/3 GN for proteins (ham, chicken), 1/6 GN for wet toppings, and 1/9 GN for lemons, chilli and herbs.
- Can a 2100 mm rail fit 8 × 1/2 GN?
- Yes—many 2100 mm benches support 8 × 1/2 GN across the rail (brand cut‑outs vary). It’s a popular high‑volume layout.
- Where do 1/1 GN trays make sense?
- In the base storage. A typical 2100 mm 1/1 GN counter with two shelf levels can store up to 8 × 1/1 GN (model‑dependent)—ideal for cold backup stock.
- Does “Class 4” guarantee my rail will hold?
- No. Class 4 (30 °C/55% RH) is a test room condition for storage sections. Rails still need lid discipline and smart layouts in hot, drafty kitchens.
11) Next steps
We’ll map your menu to GN sizes, recommend rail style and climate class, estimate running cost from the data sheet, and give you a commissioning & logging sheet aligned with FSANZ.
12) References (stable links)
- FSANZ temperature control & tools
- GN sizing (AU suppliers)
- Climate class context (storage sections)
- Tariff context
