7 Things That Commonly Go Wrong in Commercial Kitchen Projects

Commercial kitchens are one of the most technically demanding environments within any building project. Ventilation, drainage, utilities, workflow, refrigeration and fire strategy all intersect within a relatively compact footprint — often under significant programme pressure. The challenge is that many of the biggest issues are not immediately obvious during early-stage planning. In fact, some of the most expensive coordination problems we encounter are only discovered once construction is already underway. Whilst every project is different, below are some of the most common coordination issues we see within commercial kitchen developments — and why early operational planning matters. 1. Insufficient Ceiling Void Allowance for Kitchen Ventilation Ventilation systems are frequently underestimated at early design stages. Commercial kitchen extract ductwork can become extremely large, particularly where projects involve: high-volume cooking, solid fuel appliances, central production, or long duct runs to atmosphere. By the time the catering design is properly developed, it is not uncommon to discover there simply isn’t enough ceiling void space to coordinate: extract ductwork, supply air, fire systems, structure, lighting, and other M&E services together. This often leads to redesign, reduced ceiling heights or expensive rerouting later in the project. Early-stage coordination of the kitchen layout and ventilation strategy is critical. 2. Incoming Electrical Capacity Underestimated for Modern All-Electric Kitchens As projects move toward Net Zero and decarbonisation strategies, many developments are now pursuing all-electric kitchen solutions. Whilst this can bring operational and sustainability benefits, the infrastructure implications are significant. Modern induction kitchens, combi ovens, warewashing systems and refrigeration equipment can place substantial demand upon the building’s electrical infrastructure. In some cases, projects may require: upgraded incoming supplies, transformer upgrades, additional plant space, or extended DNO approval periods. These risks are far easier to manage when identified at feasibility stage rather than after MEP strategies have already been developed. 3. Coldroom Condenser Locations Identified Too Late Refrigeration coordination is another area frequently overlooked during early planning. Walk-in coldrooms may appear straightforward on plan, however the associated remote refrigeration plant requires careful consideration in relation to: pipe routes, maintenance access, acoustic control, external plant locations, and planning restrictions. Long refrigeration pipe runs can add substantial cost to projects and often become late-stage contractor variations once routes are properly understood. We regularly see projects where kitchen layouts have been approved before condenser locations have even been discussed. 4. Fire Shutters, Counters & Service Points Clashing During Coordination School serveries, hospitality counters and pass areas often involve multiple overlapping systems: fire shutters, counters, tray slides, glazing, lighting, ventilation, and customer circulation. One of the more common issues we encounter is where automated fire shutters cannot safely close because counters or tray slides obstruct the required drop zone. Problems like this are rarely caused by poor workmanship — more commonly they result from insufficient coordination between specialist packages during design development. Simple operational validation exercises early in the process can prevent significant redesign later. 5. Inadequate Drainage & Grease Management Planning Drainage strategy is rarely glamorous, but when it goes wrong it quickly becomes operationally critical. Commercial kitchens produce large volumes of: fats, oils, grease, food debris, and wash-down water. Without proper planning, projects can encounter issues such as: inaccessible grease traps, insufficient drainage falls, blocked systems, poor maintenance access, and operational downtime. Certain equipment also creates specialist drainage requirements which may affect floor slab coordination and underground services layouts. Drainage should always be considered alongside operational workflow rather than retrospectively coordinated later in the build. 6. Wash-Up & Clearing Strategies Not Sized for Peak Demand Wash-up areas are often treated as secondary spaces within kitchen projects, however they can become one of the biggest operational bottlenecks if undersized. The challenge is that wash-up demand is rarely steady. A restaurant may experience sudden bursts of dirty returns following service, whilst a school may need to clear hundreds of covers within a very short lunch period. Successful wash-up design is about much more than selecting a dishwasher. It also involves: tray returns, sorting space, waste handling, trolley movement, storage, ventilation, and staffing flow. Poor planning in these areas can significantly affect labour efficiency and service performance. 7. Kitchen Layouts Approved Before Workflow & Storage Requirements Are Properly Stress-Tested One of the most common issues across all sectors is kitchens being planned around available space rather than operational reality. On paper, a layout may appear efficient. In practice however, kitchens often fail because: circulation routes are too tight, storage is insufficient, prep areas are undersized, deliveries clash with operational flow, or staff movement becomes inefficient during peak periods. Storage in particular is frequently underestimated — especially within education, healthcare and high-volume operations. A successful commercial kitchen is not simply a collection of appliances. It is an operational process which should be validated against: menu style, staffing levels, throughput, service strategy, logistics, and maintenance requirements. Early operational stress-testing can significantly reduce redesign risk later in the project lifecycle. Final Thoughts Commercial kitchens sit at the intersection of architecture, engineering and operations. The earlier coordination discussions happen, the easier it becomes to avoid costly redesign and operational compromise later in the project. Whilst every project is different, the common thread behind many kitchen-related issues is simple: they are often identified too late. Early engagement between architects, M&E consultants, operators and specialist foodservice designers can help projects progress with greater confidence, improved coordination and fewer surprises during delivery.