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I just ordered 400lbs of pork butt to cook Friday morning for a Friday night church dinner. We already have 300 plates pre-sold, so figuring on 425-500 total dinners. Tomorrow I'm baking 700-800 brownies (a potheads fantasy, I know Big Grin ), mixing 120lbs of slaw, and making 5gals of sauce. Friday while the meat is cooking, I'll make the beans and brew 60gal of tea and 20 gals of lemonade. Bread is store bought. Unfortunately, the only item being cooked on my CS this time are some ribs I'll slip to the pastor when nobody's looking.

Anyway, I just wanted to illustrate how you stage different items with different cook times so everything finishes together. The same method will work on smaller quantities, trust me. Cool I'll post some pictures after the cook.
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quote:
Originally posted by Todd G.:
That's a very nice toy!


Yes it is. Got it for Father's day. Fill the top with ice, fill the blender's with mix. Select which of 6 styles of drink. Hit one button and it's all automatic (the funnel moves and provides crushed ice.

Nothing wrong with your plan, if I could ship you a few but they'd melt by the time they got there.

Great post by the way. A lot of those details are helped. Maybe we need a catering 101?
quote:
Originally posted by Todd G.:
quote:
Originally posted by jcohen1005:
Might make another batch of ABT's.


If you make a few extra, I might buy them from you. About 1500 ABT's ought to be enough. Let me know when they'll be ready. Smiler


I think making a few dozen are a pain in the Butt(no pun), couldn't fathom making hundreds or thousands.

Good luck this weekend, maybe a few pic's would be appreciated. I'd just like to see that much pork, only time I see 400lbs is when it has four legs and snorting around the pen.
Well, we sold 400lbs of BBQ(~250# finished weight). We had enough left over to make a sandwich, so it worked out perfect. Kind of scary at first though when we were maybe 60% through the food at 6:00, and we were planning to serve 5:00-8:00. Also, as of 6:00, most of the people we sold to were walk-ins that had not pre-purchased tickets. They just saw our signs and stopped in. Gotta love the way folks in North Carolina gobble up the Que. I was sure we were going to run out, but we didn't.

Since I'm stuck in Raleigh NC between two warring factions in the BBQ world, I split the difference and try to wear the colors from both groups, Eastern and Lexington style BBQ. I used a rub that was 2 parts garlic salt, 1 part paprika, and 1/2 part cayenne pepper. This give a nice crust and a little bite, which is then offset by the slightly sweet Lexington sauce. Everybody seems happy, and I didn't see any food on the plates in the trash. I was a happy cook. Big Grin

Here's a picture of my cooker loaded to the gills with butts. This was load 2.5. I cooked one load with 24 butts Thursday night/Friday AM, then another 26 butts went on at 8:00am, and when the smaller of those came off around 2:00pm, I put the last 6 butts on, which can be seen in this photo in the front row, left mostly.

The last 100 people or so got Bush's beans since we ran out of the beans I cooked (16gal from me and ~4gal from can). Volunteers and portion controls don't always work as planned. Mad No Christina, just one 4oz spoodle of beans, not three please dear!

We used 8gal of Lexington style sauce, 36 dozen hamburger buns, 24 dozen dinner rolls, and enough styrofoam to cause a blip in styrofoam prices next month. We had about 2gal of slaw left over, and some brownies which following my lead, the volunteers ate before going home. Roll Eyes But after everything was counted, about $4000 was raised for charity.

Used 2-20# tanks of propane in about 20 hours of cooking at a constant 300*. $27 dollars for gas isn't bad. Still more than a CS, but a lot less than wood or charcoal. And I got the most beautiful smoke ring you've ever seen without a piece of wood being burned anywhere near the cooker. I still can't figure that out. And I use the pancake flipper to pull the rear most butts off. It's easier that way.

I'm pretty certain that I contracted swine flu though, as I've been sore for the last 36 hours.



Here are my signs, or banners rather, 3'x6'. I thought about these for days and days, but in spite of being horribly complex, they seem to work.



Last edited by Former Member
Hi Todd. Thanks for report. Interesting! Those numbers are hard for me to imagine.

Is that a typical size BBQ gig for you? What's the smallest group you take on?

How long did it take to pull that much pork? Was the resulting 250# about what you prefigured?

White/red slaw?

How many people helped prepare food?
quote:
Originally posted by redoakNC:
Is that a typical size BBQ gig for you? What's the smallest group you take on?

How long did it take to pull that much pork? Was the resulting 250# about what you prefigured?

White/red slaw?

How many people helped prepare food?


As a catering gig, I normally will only do onsite cooking for 100+ people, but this year has been so slow that I'll do it for 50 people if it's local and I like the people. I do delivery for 25+ all the time with pork, brisket, chicken, etc. I cater a lot of sports teams this time of year at their place of play. The soccer/softball teams especially like this since they don't have to go wait in line at a restaurant and then rush back to the fields when they're playing a tourney.

The fundraiser jobs I do vary as to their delivery method. Within the BBQ realm I do BBQ plate dinners, take home family packs (2# of BBQ[packed quart], a couple of pint sides, 8 pack of buns, and dessert), and whole butts. It all depends on what the org wants. I would say that most of those fall between 300-500 meals, but some can hit 1000+. It depends on the location of the event, the timing, the food being offered, and how hard the org works to promote it. BBQ always sells in NC, but in the fall Brunswick stew is popular also, as are fish frys, shrimp boils, and oyster roasts. Flounder and peanut oil have gotten so expensive that fish frys are hard to make money with unless someone donates the materials, but whiting can still be sold for a reasonable price and that's good too.

I did two fundraisers for a hockey team last fall that sold about 900 family meals each event. That's 900 x 2#, plus all the sides and desserts. So that's about 3200# of raw weight in meat. About half of that was cooked in my Amerique and 008, and then mixed in with purchased meat from a local commercial BBQ producer. I ran my Amerique and 008 pretty much 24/7 for a month at the absolute limits of their capacity. And then I did it again for the same team 4 months later. Worked flawlessly. (The meat in these packs was sold frozen for food safety, and also because there's no way for me to produce that much meat inside a serving window) The team then "assembled" the packages for pickup at their home rink.

The meat this weekend was partially pulled and partially chopped(mixed) which looks really nice on a plate. It was an ongoing process, but the first batch of 24 butts took about an hour to process, then panned with sauce and placed in a cooler waiting for service. The last batch was pulled from the cooker as needed about 6 at a time.

I'm guessing about finished weight. I've done enough of these where I did weigh the finished meat that I know what my yields are going to be. I started out with 417# actual weight, and I figured for 58% yield cooked to 190* internal. 58% would have netted me 242#. I must have been pretty close based on final sales and the other sides being pretty close at the end.

White slaw. I wanted to offer red too, but the church thought it would confuse people. But I did put out some mustard sauce just to see their faces. They used about 1/2 gal, so someone must have tried it.

One person helped with food prep. He chopped and pulled meat, and made most of the brownies. He got there as the meat was coming off at 8:00am and he was a chopping/pulling/brownie making machine for the rest of the day. 4 other people came in at 4:00ish to help serve. 1 each for meat, beans, slaw, and dessert. Bread and drinks were self serve. I did everything else.

There is a big high pressure burner mounted on my cooking trailer that is behind the cooker (couldn't see it in the picture) At 8:00am when the second batch of meat went on, I brewed the tea on the burner. While it was steeping, I made the lemonade. Then I pulled and sweetened the tea, finishing 20 gals, and then fridging the remaining concentrate for later.

When tea was finished, I put on a pot of sauce. Vinegar, spices, simmer for 1/2 hour, then add water and other ingredients. (I had to do these things sequentially because I only have one big stainless steel pot. I have a bunch of aluminium pots, but I think they make the tea taste funny, and if you make sauce in them they fall apart after a few batches from the vinegar. So I need to spring for a new SS pot soon.)

While the sauce was simmering I mixed up the slaw. Pre shredded cabbage, carrots, mayo, vinegar, sugar. 120# of slaw in 30min. Done. Lets see Rachel Ray do that! (Pre shredded cabbage is available nationally from restaurant produce suppliers, most of which will sell to the public if you pick it up. This is different from the stuff in the grocery store. I can get as little as 10# at a time, with a bag of shredded carrots and purple cabbage included. Beats doing it by hand for sure)

My helper started brownies about 12:noon. The church kitchen had double ovens and I brought 12 half sheet pans so it was just a matter of mixing the batter and baking 4 pans at a time for the next few hours. A few minutes to mix, then 30 minutes to wait.

While the first load of brownies was in, we had lunch. I tossed a couple of cajun spiced chickens in on top of the butts with the 8:00 load and they were ready, so we dined on chicken, slaw, and beans from the can. Tasted pretty good.

After lunch, I chopped 5# of bacon and browned it in my giant braising pan. Then I sauteed off 5# each of onions and green peppers in the bacon grease. When they were soft, I added the juice from the bean cans, brown sugar, mustard powder, corn starch, and a gallon of dark, sweet, and smokey BBQ sauce. I don't remember the brand. Anyway, this thickens up nicely and is then added to the beans which are in a cooler, then mixed. I used a combination of Bush's baked beans, generic pork & beans, light red kidney beans, pinto beans, and giant butter beans. Then these are portioned into full sized disposable chaffer inserts and placed in the oven after the brownies are finished. (I should point out that everyone EXCEPT Pags, likes my beans Smiler)

We were pretty much finished by 3:00. I went home and took a (much needed!!!) shower and came back at 4:00 looking and smelling much better. Pre shower, there was an hour or so where the flies were starting to form a fan club for me.
Last edited by Former Member
I have no doubt Smokin's beans are excellent. My feelings aren't hurt.

Also, cooking for a crowd isn't as hard as it sounds. You need control over the menu so you don't end up having to make 2000 pieces of finger food, but cooking 24 butts doesn't take any longer than cooking 1, just as making slaw for 10 doesn't take any longer than making it for 300 really. You have the same steps, you're just using larger quantities, so you have to have the big pots and mixing pans.

It took about 45 minutes to open, rub, and load 24 butts. After that, cook time is the same as for one butt. Then it's a question of material handling. It's not really even food any more, it a product with certain handling requirements. It must be kept cool, or hot, or it's hot and must be quickly cooled, or cool and needs to be heated. You just have to think it through and know what resources are available. This church was great even thought they didn't have a commercial kitchen. The only curve ball they threw was that their ice machine broke down last week, so we had to buy lots of bag ice. Some churches forget to mention that while they have a kitchen, it hasn't had electricity running to it in 30 years. Or that all the burners on their stove are burned out, or that they don't have potable water since their well is contaminated with pesticides. These things always happen with churches that are 30 miles away from the nearest grocery store. Funny how that works.

If you have the needed walk-in or reach-in space, and the necessary heat sources and storage containers, it's really not hard. Of course you never have all those things, so there's always a challenge to be found and dealt with. Not to mention that things get heavy when you're talking big quantities, so you'll need a bunch of big guys around to lift stuff, or a wheeled cart, or both.

I took flying lessons when I was younger, and I remember the instructor always stressing to have a plan. Know where the nearest airport or potential landing site is at all times in case the worse thing that can happen does. Catering is very similar. I ask myself 1000 times a day what I'll do if so and so happens in the next few minutes. Then I make a plan for that scenario and hope I don't have to use it.
Last edited by Former Member
quote:
Originally posted by Todd G.:...I took flying lessons when I was younger, and I remember the instructor always stressing to have a plan.... I ask myself 1000 times a day what I'll do if so and so happens in the next few minutes. Then I make a plan for that scenario and hope I don't have to use it.
Based on your experience with cooking for large groups, whats the most likely thing(s) that happens that causes the most concern and need for a plan B?
Cooking with a pig cooker, you have the potential for storms and the wind and rain that comes with them to slow the cooking down. You always need some type of appetizer to buy yourself 1-2 hours of time if this should occur.

Running out of time. Always get there on time even if you have to do some prep on site. If the client gets stressed out, you'll never make them happy even if you serve on time. Be early if at all possible.

Pit fires. Less likely with gas cookers, but still a good reason to have a Co2 extinguisher.

Fewer than the expected number of people show up, leading to massive left overs. I carry a butt load of 2.5 gal and 1 gal bags with me at all times. Sometimes the client wants it, sometimes not, but you still need a way to store/transport the food back to your kitchen or food bank.

More than the expected number of people show up. There's not much I can do about cooking more butts. I usually do have 5-10# of meat with me for just in case scenarios like these, but it won't help much if 200 show up and you were expecting 120. Then it's a quick consultation with the client and likely a trip to Sam's for pasta salad, dogs and burgers for the kids, chips for nachos, etc. Pretty much anything to stretch the meat as far as possible.

Food transportation issues. When someone dives in front of you and slams on brakes, causing a van full of food to slide forward. Don't really have a solution for this one other than to be veeeerrrrryyy careful when hauling food.

Mechanical issues. I always have a friend I can call to provide emergency pick up if my delivery vehicle conks out. Mostly I just take care of my trucks.

Dropping food. Never, ever, put all of one item on one platter. If you drop it, it's gone. Much better to have at least two bowl/platters. They look better and it's safer.

Employees not showing up to an event. I have a couple of chef friends that will come through for me if this happens. They'll either help out or they'll send someone from their restaurant to help.

Customers not showing up for an event. Have lots of contact numbers because you can end up in court over this one and you want to make sure you were in the right place at the right time even if they were not. In April, I had a fully paid and confirmed(4 days prior) wedding for 130 people not show up. I've never heard from them. Food went to the homeless shelter.

Know where your nearest grocery store is, the nearest LP gas dealer, the nearest ice source, the nearest Costco/Sam's/BJ's.

Power going out. Not really my fault, but I do events at a lot of parks under public shelters. Sometimes the power goes out for no apparent reason and can't be restored. I have a 13kw generator that goes with me to most events. Sometimes it's needed for other reasons, like a band. I score big brownie points for coming through with a solution.

These things won't affect most folks, but the more you serve, the more likely you are to run into some of these problems, especially those related to the number of guests. If you invite 24 people to your party and 20% don't show, then you have food for 5 people left over. If the party is for 150 and 20% doesn't show, you've got left over issues. That's pretty common with pig pickin's where folks invite everyone in their neighborhood, or all their business associates and some don't show.

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