MEAL DELIVERY SYSTEM DESIGN GUIDE

1. PURPOSE OF THIS GUIDE

This guide helps correctional administrators, architects, and foodservice directors design secure, efficient, tamper-resistant meal delivery systems. It covers trayline design, transport carts, insulated serviceware, delivery sequencing, contraband prevention, and operational security protocols.

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2. UNDERSTANDING CORRECTIONAL MEAL DELIVERY SYSTEMS

Meal delivery in a secure environment must balance:

• Security – contraband control, anti-tamper features, reduced ligature risk
• Temperature retention – maintaining HACCP standards across long delivery routes
• Durability – equipment must withstand daily use
• Labor realities – incarcerated individual labor at varying skill levels
• Predictable throughput – 2–4 meal periods daily under strict movement rules

Every decision — from tray type to cart placement — directly affects food safety, labor efficiency, and security.

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3. DELIVERY MODEL COMPARISON

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4. DESIGNING A SECURE TRAYLINE SYSTEM

4.1 Trayline Layout Requirements

A correctional trayline must ensure:

• Single-direction workflow (no incarcerated individual crossover)
• Restricted access to hot food wells
• Staff-supervised portion control
• Integrated diet station for special trays
• Ability to stage carts rapidly to avoid congestion

4.2 Tamper-Proofing the Trayline

• Enclosed bases
• Welded frame construction
• No removable hardware accessible without tools
• Shielded service areas
• Recessed controls on hot/cold wells

4.3 Throughput Calculation

Formula:

Trays per minute × Meal window = System capacity

Typical requirements:

• 200–600 trays/hour for jails
• 600–2,000+ trays/hour for prisons

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5. TRAY SELECTION FOR CORRECTIONAL FACILITIES

5.1 Types of Trays

Insulated trays (polymer or fiberglass)

Unitized molded trays (tamper-resistant)

Clamshell trays (for segregation units)

Cold-only or hot/cold split trays

5.2 Key Features

• Non-metallic, non-weaponizable
• Rounded edges, no cut points
• Durable under repeated high-temp washing
• Stackable for efficient staging
• Space for diet identification labels

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6. CART SYSTEM DESIGN

Transport carts are a major risk point — design matters.

6.1 Tamper-Resistant Carts

Carts should include:

• Fully enclosed chambers
• Locking or latch-secured doors
• Welded hinges
• No removable shelves without tools
• Anti-ligature handles
• Fixed or lockable casters

6.2 Cart Type Comparison

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6.3 Route Engineering

• Minimize incarcerated individual contact points
• Maintain predictable hallway flow
• Avoid blind corners and choke points
• Use pre-mapped routes approved by custody

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7. TEMPERATURE MAINTENANCE & HACCP CONTROLS

Meal delivery systems must ensure:

• Hot foods ≥140°F
• Cold foods ≤41°F

Recommended practices:

• Preheat hot carts 30 minutes prior
• Use insulated lids or domes
• Document temperatures at:
  • Trayline exit
  • Cart loading
  • Arrival in housing unit

Consider implementing digital temp monitoring for large facilities.

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8. SECURITY CONSIDERATIONS FOR MEAL DELIVERY

8.1 Contraband Prevention

• No hollow handles or open cavities
• No removable interior components
• Use carts with non-removable divider walls
• Staff-only access to cart keys or latches

8.2 Movement Control

• Deliveries must align with incarcerated individual lockdown periods
• No incarcerated individual access to carts during staging
• Carts must be supervised in hallways

8.3 High-Security Units

Use:

• Unitized trays
• Locking carts
• Staff-only tray distribution

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9. WORKFLOW: END-TO-END DELIVERY SEQUENCE

1. Trayline Setup

• Staff set up wells, utensils, diets
• Preheat or pre-chill carts

2. Tray Assembly

• Staff-only hot food service
• Controlled incarcerated individual assistance permitted on cold side (if allowed by facility)

3. Cart Staging

• Lock carts
• Log cart contents
• Custody signs off on departure

4. Transport

• Use pre-approved routes
• Escort required depending on security level

5. Housing Unit Service

• Carts unlocked by custody
• Staff serve or supervise incarcerated individual distribution

6. Tray Return

• Reverse routes or use dedicated return paths
• Return carts to dishroom staging area

7. Dishroom Processing

• Soiled carts inspected for contraband
• Trays sanitized
• Final counts verified

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10. EQUIPMENT RECOMMENDATIONS BY FACILITY TYPE

County Jails

• Compact insulated carts
• Unitized or clamshell trays
• Simple trayline with durable equipment

State/Federal Prisons

• High-capacity traylines
• Hot/cold carts with locking mechanisms
• Dedicated diet tray station
• Flight-type dish machines

ICE/Detention Facilities

• Multi-diet labeling capabilities
• Tamper-resistant mixed-temperature carts

Community Corrections

• Traditional commercial carts
• Standard insulated trays

11. PRE-INSTALLATION CHECKLIST (SUMMARY)

• Door widths accommodate cart size
• Electrical circuits available for powered carts
• Hallway turning radius fits cart dimensions
• Secure cart storage available
• Custody-approved delivery routes established
• Pre-opening staff training scheduled

(You already have the full detailed checklist — this version links to it.)

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12. COMMON DESIGN MISTAKES TO AVOID

• Using restaurant-grade carts that break under correctional conditions
• Not accounting for long transport distances
• Undersizing traylines for peak demand
• Forgetting return-flow logistics
• Overlooking contraband risks in cart interiors
• Not coordinating with custody on route timing

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Conclusion

A secure meal delivery system is more than carts and trays — it’s a coordinated workflow involving equipment, custody schedules, food safety requirements, and tamper-resistant design.

Aldevra delivers complete, correctional-grade meal delivery systems that meet the needs of jails, prisons, detention facilities, and high-security units.