Whopper patties get their flame-broiled character from a proprietary commercial broiler that cooks multiple patties at once. After cooking, Burger King uses a secondary warming system called the Hopper to melt cheese, reheat patties, and keep burgers consistently warm. Employees describe placing bottom buns and patties into the Hopper to melt cheese, while fresh buns and meat still require additional steps such as toasting buns. The Hopper is used for warming rather than cooking, and it differs from made-to-order practices at some other chains that do not use a microwave. During rush periods, patties held warm can cool slightly, leading to partially unmelted cheese and customer complaints.
"“Currently employed at BK and we put every bottom bun and patty in the 'Hopper' (trademarked microwave) to melt the cheese mostly but we still have to do it with just bun and meat, even to fresh meat, and we toast every bun fresh, so, just policy I suppose.”"
"“During rush periods, Burger King's operational system requires them to flame-broil patties in batches, and then hold them warm until an order comes in. Tragically, the patty temperature can drop slightly while it's hanging out in the warmer, causing the cheese to remain partially unmelted.”"
"“The Hopper is most often used to melt cheese, reheat patties, or simply to ensure the entire burger feels warm when it's served. Burger King workers explain online that this specialty oven is to ensure melted cheese and consistent temperatures, but it's not an actual cooking method.”"
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