Assembly
50 lunches: 30 turkey, 20 ham. Two or three people, one line: spreader → builder → bagger. Ten at a time. Quantities come from option A; the first delivery packs one cube in the biggest, most structural frame cube.
Per lunch
BREAD2 slices
100 needed · 6 loaves run 16–20 slices — count before you start; heels close any gap
100 needed · 6 loaves run 16–20 slices — count before you start; heels close any gap
TURKEY4 oz · about 4–5 slices
30 lunches · 120 oz = the 3 twin packs · weigh the first three on the scale, then count
30 lunches · 120 oz = the 3 twin packs · weigh the first three on the scale, then count
HAM4.8 oz · about 5–6 slices
20 lunches · 96 oz = the 2 twin packs
20 lunches · 96 oz = the 2 twin packs
CHEESE2 slices
100 of 104
100 of 104
LETTUCE1 romaine leaf
5 hearts, washed, dried, torn to slice size
5 hearts, washed, dried, torn to slice size
MAYO1 tbsp (15 g) on the bottom slice, edge to edge
about 25 oz of 64
about 25 oz of 64
MUSTARD1 tsp (5 g) on the top slice, thin, edge to edge
about 8 oz of 60
about 8 oz of 60
CHIPS1 bag
54 · 4 spare
54 · 4 spare
MANDARIN1, washed
30–40 in the two bags
30–40 in the two bags
COOKIE1, wrapped in a napkin
48 in two packs — 2 short: add a third pack ($7.99, still $12.80 under) or two lunches go without
48 in two packs — 2 short: add a third pack ($7.99, still $12.80 under) or two lunches go without
WATER1 bottle, handed out at the pad
80 · rides as sealed cases in the cube, never in the bag
80 · rides as sealed cases in the cube, never in the bag
NAPKINS2 · one wraps the cookie, one folded on top
1,040
1,040
LUNCH BAG1 · #4 kraft, folded twice, marked
500 · a 16.9 oz bottle does not fit
500 · a 16.9 oz bottle does not fit
SANDWICH BAG1 · option B only
580 Ziploc · option A builds at the far end instead
580 Ziploc · option A builds at the far end instead
Tools and setup
·6 ft table (or two), washed then sanitized — 1 tbsp unscented bleach per gallon of water, air dry
·cutting board, serrated bread knife, a second knife for the lettuce
·kitchen scale in ounces
·two 1 tbsp spoons for mayo, the mustard bottles as squeeze bottles
·5 sheet pans or trays — one per 10 sandwiches
·nitrile gloves (the 400 box), paper towels, a permanent marker, masking tape
·2 coolers (25 bags each) with frozen ice packs, or fridge space
·2 crates or boxes that fit 25 upright bags each (5 × 5), 1 cam strap for the water
·the manifest: this page's build sheet, printed twice
Before anything
1Cold stays cold
Meat and cheese stay in the fridge (≤ 40 °F) until the line is set. Write the time the first meat pack opens on the manifest; the pack must fly within 2 hours of it (1 hour if the room is over 90 °F).
Meat and cheese stay in the fridge (≤ 40 °F) until the line is set. Write the time the first meat pack opens on the manifest; the pack must fly within 2 hours of it (1 hour if the room is over 90 °F).
2Count
Open and count every line in the table above. Fix shortfalls now (bread slices, the two missing cookies). Wash the mandarins and the lettuce.
Open and count every line in the table above. Fix shortfalls now (bread slices, the two missing cookies). Wash the mandarins and the lettuce.
3Lettuce
Separate 50 leaves, wash, spin or pat dry, tear each to the size of a slice. Wet lettuce is the thing that makes a bagged sandwich soggy.
Separate 50 leaves, wash, spin or pat dry, tear each to the size of a slice. Wet lettuce is the thing that makes a bagged sandwich soggy.
4Line
Three stations in a row: spreader, builder, bagger. Gloves on; new gloves whenever you switch stations or touch anything that isn't food. Trays of ten move down the line.
Three stations in a row: spreader, builder, bagger. Gloves on; new gloves whenever you switch stations or touch anything that isn't food. Trays of ten move down the line.
The sandwich · ten at a time
5Lay out
10 bottom slices in two rows of five on a tray; 10 top slices on a second tray. Match slices from the same loaf.
10 bottom slices in two rows of five on a tray; 10 top slices on a second tray. Match slices from the same loaf.
6Spread
Mayo: 1 tbsp on every bottom, spread edge to edge with the back of the spoon (edge to edge seals the bread). Mustard: 1 tsp on every top in a zigzag, spread thin, edge to edge.
Mayo: 1 tbsp on every bottom, spread edge to edge with the back of the spoon (edge to edge seals the bread). Mustard: 1 tsp on every top in a zigzag, spread thin, edge to edge.
7Cheese
2 slices on the mayo side, offset so they cover the square.
2 slices on the mayo side, offset so they cover the square.
8Meat
Turkey 4 oz on 30 sandwiches, ham 4.8 oz on 20. Weigh the first three portions, then count slices. Fold each slice in half and shingle the folded slices across the cheese: folding gives height and stops the meat sliding out at the cut.
Turkey 4 oz on 30 sandwiches, ham 4.8 oz on 20. Weigh the first three portions, then count slices. Fold each slice in half and shingle the folded slices across the cheese: folding gives height and stops the meat sliding out at the cut.
9Lettuce
1 dry leaf flat on the meat. It sits between meat and the mustard slice and shields that slice.
1 dry leaf flat on the meat. It sits between meat and the mustard slice and shields that slice.
10Close
Mustard slice down. One press with a flat palm — enough to seat it, not enough to flatten it.
Mustard slice down. One press with a flat palm — enough to seat it, not enough to flatten it.
11Cut
One diagonal cut, corner to corner, serrated knife, one long draw, no sawing. Two triangles. Wipe the knife every ten sandwiches; new board if the turkey/ham order changes.
One diagonal cut, corner to corner, serrated knife, one long draw, no sawing. Two triangles. Wipe the knife every ten sandwiches; new board if the turkey/ham order changes.
12Bag the sandwich (option B)
Both halves into one Ziploc, cut edges together, crusts out, flat. Press the air out from the bottom up, seal, then write T or H in the top-right corner with the marker. Option A: the supplies fly as-is and these steps run at the landing pad after delivery.
Both halves into one Ziploc, cut edges together, crusts out, flat. Press the air out from the bottom up, seal, then write T or H in the top-right corner with the marker. Option A: the supplies fly as-is and these steps run at the landing pad after delivery.
The lunch bag
13Order inside the bag
Square the bottom of a #4 kraft bag. Sandwich first, flat on the bottom, cut side up. Chips standing against one wall. Mandarin in the opposite corner. Cookie wrapped in one napkin, laid on top of the sandwich. Second napkin folded on top of everything.
Square the bottom of a #4 kraft bag. Sandwich first, flat on the bottom, cut side up. Chips standing against one wall. Mandarin in the opposite corner. Cookie wrapped in one napkin, laid on top of the sandwich. Second napkin folded on top of everything.
14Close
Fold the top over twice, one inch each fold, crease hard. No tape needed; tape only if a bag won't hold its fold.
Fold the top over twice, one inch each fold, crease hard. No tape needed; tape only if a bag won't hold its fold.
15Mark the fold
Three marks on the fold, left to right: T or H · the order's middle digits (10001) · the lunch number. Turkey is T01–T30, ham is H31–H50. Every bag reads: T07 10001.
Three marks on the fold, left to right: T or H · the order's middle digits (10001) · the lunch number. Turkey is T01–T30, ham is H31–H50. Every bag reads: T07 10001.
16Water
No bottle in the bag. Water flies as two sealed cases in the cube and is handed out one per bag at the pad.
No bottle in the bag. Water flies as two sealed cases in the cube and is handed out one per bag at the pad.
Tally and hold
17Count both ways
Line the bags up by number. Count 30 T + 20 H forward, then 20 H + 30 T back; the totals must match (50) before anything goes in a cooler. Tick each number on the manifest.
Line the bags up by number. Count 30 T + 20 H forward, then 20 H + 30 T back; the totals must match (50) before anything goes in a cooler. Tick each number on the manifest.
18Hold cold
Bags upright in the coolers, 25 each, fold up, numbers reading from above: cooler L = T01–T25, cooler R = T26–T30 + H31–H50. Frozen ice packs on the sides, not on top of the bags (they crush the bread). Lids shut until loading.
Bags upright in the coolers, 25 each, fold up, numbers reading from above: cooler L = T01–T25, cooler R = T26–T30 + H31–H50. Frozen ice packs on the sides, not on top of the bags (they crush the bread). Lids shut until loading.
19Clean down
Trays, knife, board washed; table wiped; gloves off. Spares (4 chips, extra mandarins, the opened mayo and mustard bagged in a Ziploc) set aside for the cube.
Trays, knife, board washed; table wiped; gloves off. Spares (4 chips, extra mandarins, the opened mayo and mustard bagged in a Ziploc) set aside for the cube.
Pack the cube
20Floor: water
Both water cases on the cube floor, centred, long sides across the cube so the 88 lb sit in the middle. One cam strap across both cases to the cube's floor anchors.
Both water cases on the cube floor, centred, long sides across the cube so the 88 lb sit in the middle. One cam strap across both cases to the cube's floor anchors.
21Sides: lunches
Cooler L against the left wall, cooler R against the right wall (or the two crates, bags upright, 5 × 5, folds up). Equal count each side keeps the cube balanced about its centre.
Cooler L against the left wall, cooler R against the right wall (or the two crates, bags upright, 5 × 5, folds up). Equal count each side keeps the cube balanced about its centre.
22Fill: nothing moves
Spares and the paper goods (napkin pack, remaining kraft bags, gloves box) wedged into the gaps between coolers, cases and walls until nothing can shift. This is the puzzle: every piece holds the next one.
Spares and the paper goods (napkin pack, remaining kraft bags, gloves box) wedged into the gaps between coolers, cases and walls until nothing can shift. This is the puzzle: every piece holds the next one.
23Shake test
Lid on. Lift one edge two inches and let it drop. Nothing should be heard moving. If something moves, open and re-wedge.
Lid on. Lift one edge two inches and let it drop. Nothing should be heard moving. If something moves, open and re-wedge.
24Manifest
One copy in a Ziploc taped inside the lid; one copy stays at 2675. Both carry the time the first meat opened and the tally signature.
One copy in a Ziploc taped inside the lid; one copy stays at 2675. Both carry the time the first meat opened and the tally signature.
25Label
The palinPack label on the cube's outward face: order number, from → to, 50 lunches, weight, time out of the fridge.
The palinPack label on the cube's outward face: order number, from → to, 50 lunches, weight, time out of the fridge.
Mount and pickup · at 2675
26Mount at c0
Cube into the frame cube, [up ^], label facing out. T100-style clamps at the four corners, tightened in opposite pairs (1, 3, 2, 4) so the cube seats square. Property-rated cables and anchors to the frame; tug-test each one.
Cube into the frame cube, [up ^], label facing out. T100-style clamps at the four corners, tightened in opposite pairs (1, 3, 2, 4) so the cube seats square. Property-rated cables and anchors to the frame; tug-test each one.
27Pickup checklist
Label matches the order number · tally is 50 and signed · time out of fridge is written and inside the 2 h window at the planned landing · ice packs were frozen · shake test passed · clamps and anchors tug-tested · bill status noted. Then set the order to packed.
Label matches the order number · tally is 50 and signed · time out of fridge is written and inside the 2 h window at the planned landing · ice packs were frozen · shake test passed · clamps and anchors tug-tested · bill status noted. Then set the order to packed.
28Release
When the flight is approved and the pad is clear, set the order to in flight. The clock keeps running.
When the flight is approved and the pad is clear, set the order to in flight. The clock keeps running.
Arrival · at 2690
29Receive
Set the order to delivered. Open the cube; manifest out of the lid; count the bags both ways against it (30 T + 20 H, then back).
Set the order to delivered. Open the cube; manifest out of the lid; count the bags both ways against it (30 T + 20 H, then back).
30Cold or serve
Bags straight into cold storage, or served now. Serve within the 2 h window; past it, the sandwiches don't get served.
Bags straight into cold storage, or served now. Serve within the 2 h window; past it, the sandwiches don't get served.
31Water
One bottle handed out with each bag.
One bottle handed out with each bag.
32Returns
Cube, both coolers or crates, ice packs, cam strap and the manifest copy go back on the next flight or by road. The frame cube stays mounted.
Cube, both coolers or crates, ice packs, cam strap and the manifest copy go back on the next flight or by road. The frame cube stays mounted.
Build sheet · SVG, for the station wall
palinPack label · SVG
Load plan · 149.75 lb in c0