Thoughts???

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The only other thing I can think of but would be difficult to fabricate would be to have a flip open door and have a removable RF plate or removable catch pan, sort of like the Weber Grill Genesis has a slide out grease catch.
 
So you have you baffle plate already in.
Personally for something your size I'd make a light weight (1-2mm) drop in catch tray with 30mm high sides to sit on top of your baffle so you can easily remove it and scrap it clean each night.
Foil would work but it's a large surface to cover and over a year the cost of foil would probably have covered the cost of the removable tray.
FYI. Food looks great
 
Yeah, I'm thinking lightweight sheet metal pans, custom fit for your cooker.  Sheet metal shop should be able to knock those out for you pretty cheap.  Have spares so you can as SQWIB said change them out on the fly.  The thin metal would not change the dynamics of your cooker and make cleaning up simple.  
 
Build two removable shallow plates 1/2" - 1" high or so, to fit the RF plate but have wiggle room to remove, put handles on the plates for easy removal.
During cooks one plate can be removed set aside to cool as the other one is placed inside . No loss of production time as this can be done on the fly.
If you scrape each time that cuts into your production time. The removed plate once cooled enough to handle then can be cleaned and set aside till its time to change it out again.


GOOD PLAN !!!!
 
Think ill use full size sheet pans, and build a rack with 1/2" round stock, . The lip on the pans should sit nicely on the round stock, and they will be nice and light to handle
 
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