case study

Engineering the Next-Generation Containerized Kitchen

Enhanced containerized kitchen (CK-E)
Program

Aerial view of a miniature model of a building with surrounding structures on a flat surface, including roads, vehicles, and equipment.

the Customer:

U.S. Army

Description:

The Army Containerized Kitchen (CK) is a self-contained mobile field feeding system configured in an 8-ft by 8-ft by 20-ft expandable container-shelter that provides a rapidly deployable food preparation capability. The CK can prepare any type of food, including military UGR-H&S and UGR-A rations and is transportable by a 7 1/2 ton, 4-wheel trailer and capable of feeding up to 800 soldiers three times per day.

Military personnel serving food at a buffet line inside a multipurpose tent, wearing camouflage uniforms and black gloves.

Our task was to upgrade and modernize the Army’s largest field feeding platform into a safer, more user-friendly, and energy-efficient system by integrating Babington’s closed-combustion appliances, engineering an improved wing wall and winch system, and redesigning the mechanical room for better access, safety, and serviceability. The objective: extend the CK’s operational life, improve crew safety and comfort, and lower long-term sustainment costs—while maintaining the system’s full feeding capacity.

the objective:

The Army’s legacy CK—originally fielded in 2001—is aging and increasingly unsustainable, with many units approaching 25 years in service. The core challenge: develop an upgraded system that solves key performance and safety issues while reusing as much of the existing CK infrastructure as possible. The effort required targeted engineering by the Babington team to correct known problem areas and introduce value-added enhancements for improved functionality.

Key issues included:

  • Failing wing walls, degraded flooring, and rust-prone components.

  • Excessive internal heat and noise from open-flame appliances.

  • Ventilation failures causing carbon monoxide (CO) exposure risks, and underperforming ECUs.

  • Complex generator servicing and excessive logistical burden.

the challenge:

the Babington solution

Military green mobile trailer with stairs and stairs with railing, covered sides, located outdoors with trees and a building in the background.

  • Wing Wall Retrofit: Lightweight aluminum mono-panel flooring with integrated jacks, water drainage, and non-slip surface—eliminating plywood degradation and improving safety.

  • Closed-Flame Appliance Integration: Replaced legacy open-flame MBUs with JP-8 fired closed-combustion Airtronic Burner appliances, reducing heat, noise, and CO risks.

  • Integrated and Insulated Support Structure: Permanent mounted and collapsible support frame with insulated ceiling, enabling fast, safe setup with fewer personnel.

  • Generator Slide-Out Assembly: Enabled safe fueling, improved airflow, and easier maintenance by relocating the 10kW AMMPS generator on a sliding mount.

  • Integrated Thermal Modeling: Babington conducted CFD modeling and thermal analysis to evaluate interior heat loads and guide ECU selection.

  • LED Lighting Upgrade: Replaced legacy fluorescent fixtures with energy-efficient LED systems, maintaining normal, blackout, and emergency lighting functionality.

key innovations:

Isometric illustration of a green shipping container with a modular design, mounted on a flatbed trailer with dual wheels.
A modular, container-style structure with solar panels on the roof, various equipment and storage units inside, and a ladder on one side, designed for sustainable or off-grid use.
Green mobile modular unit with stairs leading to entrances on both sides, open side revealing interior equipment, and windows, set on adjustable supports.

CK-E Deployment: From Transport Mode to Operational Mode

The outcome

The Enhanced Containerized Kitchen (CK-E)

BEFORE: Legacy CK System

  • Mobile kitchen or food truck interior with stainless steel counters, shelves, and kitchen tools hanging, including ladles and spatulas.

    Interior of Legacy CK Kitchen

    Inside the legacy CK, showing the central cook station beneath the overhead exhaust hood and ventilation system, with the food preparation area behind it.

  • A soldier in camouflage uniform serving cooked vegetables from a large pot into a metal container

    Operator Exposure to Heat and Emissions

    A food service specialist prepares meals over an open-flame MBU burner, working in extreme heat and directly exposed to carbon monoxide (CO) and combustion byproducts.

  • A large metal pot of boiling water with green beans is sitting on a propane burner.

    Open-FLame Combustion

    A close-up of the MBU’s open flame, highlighting the intense radiant heat and direct release of combustion byproducts into the kitchen environment.

  • A dismantled military aircraft canopy inside a warehouse.

    Degraded Wing Wall

    The CK’s expandable wing wall showing signs of structural fatigue, water damage, and corrosion after years of field use, environmental exposure, and failing winch and cable systems.

  • Metal table or work surface with holes, in an industrial or workshop setting.

    Damaged Flooring

    The CK’s original plywood floor, degraded by trapped moisture, corrosion, and heavy foot traffic in high-use zones.

  • Interior of a grow tent with a reflective white interior, black marbling pattern, and a square window with green trim. A black hose or tube is attached at the top of the window. Part of a wooden railing is visible through the window. The floor is gray and textured, and the tent is supported by white poles.

    Deteriorating Canvas

    The insulated fabric cover exhibits tearing, UV wear, and water intrusion—contributing to poor insulation, difficult setup, and costly replacement.

AFTER: Upgraded CK-E System

  • Industrial kitchen with stainless steel appliances, including refrigerated cabinets, a countertop, and exhaust hoods, inside a white-walled room.

    Modernized Kitchen Layout

    The interior of the CK-E shows closed combustion appliances and an open floor plan that improves workflow, thermal comfort, and operational flexibility.

  • People lining up and serving food in a kitchen, with food trays and sandwiches on the counter.

    Flexible Serving Line

    Foodservice personnel operate efficiently moving through the serving line. The new kitchen layout supports both internal and external serving line configurations, allowing units to adapt based on mission needs and customer preference.

  • Image of industrial refrigeration or cooling equipment with two open access panels revealing compressors inside.

    Closed Combustion Eliminates Open-Flame Hazards

    Airtronic closed-combustion burners are integrated into all CK-E cooking appliances—eliminating open-flame hazards and dramatically reducing internal heat, noise, and CO exposure.

  • Large industrial green hatch door opened in a factory setting, revealing an interior with glass panels and machinery.

    Lightweight Wing Walls with Electric Winch

    Lightweight, drainable wing walls feature corrosion-resistant materials . An electric winch system replaces the legacy manual cable setup—improving safety, reliability, and ease of deployment.

  • Interior of a small enclosed space with white fabric walls, some with black openings and straps. Part of a stainless steel kitchen appliance is visible on the left. Fluorescent lights are mounted on the ceiling.

    Insulated Fabric Support Structure and Durable Flooring

    An integrated fabric support structure also serves as an insulated ceiling—improving thermal comfort, setup time, and overall safety. The upgraded, water-resistant flooring withstands moisture and heavy use, eliminating the degradation issues of the original plywood design.

  • Military green generator with open doors, exposing internal components, positioned on a wooden pallet with a fuel container nearby in an industrial setting.

    New Mechanical Room with Slide-Out Gnerator

    The mechanical room has been reconfigured to include a slide-out generator mount assembly, allowing safe and easy access for fueling, maintenance, and operation. This design improves airflow and reduces noise inside the kitchen during use.

Download CK-E Brochure

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