New Product Development Services for Quick Service Restaurants
In 2011, Prince Castle engaged our new product development services to design a series of continuous feed bun toasting machines for quick service restaurants that would be able to toast a variety of different bun sizes including the middle bun of a McDonald’s Big Mac. With client input and DiMonte Group innovation, we were able to develop a reliable, user friendly, and NSF approved product that solved the problem. We delivered several fully functioning prototypes that McDonald’s could try in their test kitchen, and also developed variations for Burger King and Jack in the Box.
Product Development
Toasting the club section, the middle bun, of a Big Mac on both sides was exactly the kind of challenge our new product development services are built for. Our solution toasted the club section between two teflon belts. The system is designed with self-aligning belt technology that makes the belts very easy to remove, clean, and re-install. All the belts in the system are driven off the same motor through a gear transmission we developed.
Safety and serviceability are built into all of our new product development services, so we designed internal insulation and ventilation to keep every contact point below 140°F. The toast in-feed area features a heat shield to keep the touch points at the top of the toaster cool. We also incorporated safety door switches that turn the toaster off when a service door is open. The electronics are housed in a quick access area at the base of the machine that is sealed away from crumbs and grease.
Where is it now?
Prince Castle’s DCFT is currently in use in many quick service restaurants around the world. From prototype to restaurants worldwide, the DCFT shows how new product development services can deliver a product that lasts. If you have ordered a Whopper recently, the buns were probably toasted using one of these machines!
