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Cook-Chill Equipment Applications and Best Practices
- 1. Cook-Chill Applications and Best Practices Feb. 25, 2014 This deck is part of a free webcast from Foodservice Equipment & Supplies magazine that will be available until Feb. 2015. The link is on Slide 6.
- 2. Objectives Discuss cook chill to: Develop a better understanding of this practice. Discuss the advantages of this food preparation method. Explore what’s driving interest in cook chill. List the considerations operators should weigh when implementing cook chill. Review the process of going to cook chill. Answer your questions. ©2014 Foodservice Equipment & Supplies
- 3. Meet Our Panelists Connie Dickson Principal Robert Rippe & Associates ©2014 Foodservice Equipment & Supplies
- 4. Meet Our Panelists Paul Hysen Principal Hysen Associates ©2014 Foodservice Equipment & Supplies
- 5. Meet Our Panelists Paul Mackesey Principal Mackesey and Associates ©2014 Foodservice Equipment & Supplies
- 6. Thanks to Our Sponsors To access the archive of the webcast go here: www.fesmag.com/cookchill
- 8. Experts in Cook Chill Packaging & Equipment Processing Equipment • • • • • • Steam-Jacketed Kettles Tumble Chillers Jet Cook Systems Cook Quench Chill Systems Sous Vide Systems Recipe Management Software Food Packaging & Accessories • • • • • • Cook Chill Bags Cook Tank Bags Sous Vide Packaging Box Liners Ring Stands Heat Sealers / Clippers plascongroup.com | 888.584.4422
- 9. ThermalRite’s CypenVac™ Technology Honored with Kitchen Innovations® 2014 Award presented by the National Restaurant Association, Restaurant Hotel-Motel Show® The Secret’s in the Wall! ThermalRite’s CypenVac™ Technology , offered on its blast chillers and freezers, can reduce energy consumption by up to 43%! Faster Cooling – Safer Eating! ThermalRite Blast Chillers can help comply with HACCP guidelines – cool cooked food faster than other units available (straight from oven to chiller) …from+194°F to +37°F in just 90 minutes! Visit Thermalrite.com . Ask us for more information!
- 10. Defining Cook Chill Cook chill is an advanced processing technique that uses specific conditions to prepare food for consumption at a later time. Got its start in Swedish hospitals Cornell identified cook chill can help operators make better use of labor during slower periods. Economically driven to help industry improve efficiency ©2014 Foodservice Equipment & Supplies
- 11. Defining Cook Chill A Form of Advanced Food Prep No direct link exists between cooking and serving with this process. Holding could last days or weeks. Suitable for a variety of foodservice operators Offers a range from sauces and soups to center of the plate. ©2014 Foodservice Equipment & Supplies
- 12. Advantages of Cook Chill Why operators may turn to cook chill: Greater menu variety Efficient use of seasonal and locally sourced ingredients Quality control Minimizes food waste by limiting over production ©2014 Foodservice Equipment & Supplies
- 13. Advantages of Cook Chill More reasons to use cook chill: Efficiency in production Cost reduction Address storage and space issues Deal with peak traffic periods better ©2014 Foodservice Equipment & Supplies
- 14. Renewed Interest in Cook Chill Cook chill can be a supplemental production system for many applications: Increased interest in using fresh, seasonal ingredients Address local purchasing requirements Meet government nutritional requirements Works well with components operators may use frequently ©2014 Foodservice Equipment & Supplies
- 15. Cook-Chill Considerations Foods suitable for cook chill: Items operators can cook and quickly chill to allow for safe holding. Good fits could include stews, chili, casseroles and even meat Bad fits include salads ©2014 Foodservice Equipment & Supplies
- 16. Cook-Chill Considerations What operators need to know: Understand the sanitation issues. Study your menu to determine what items might be suitable for cook chill. Identify which recipes may require modification. Determine what method you will use to quickly chill product to food-safe temperatures. ©2014 Foodservice Equipment & Supplies
- 17. The Cook-Chill Process Holding Product How fast you can chill impacts how long you can store a product. Approach can be very sophisticated (tumble chillers or blast chillers) or pretty simple (ice wands and baths) ©2014 Foodservice Equipment & Supplies
- 18. The Cook-Chill Process Holding Product The type of product impacts shelf life. Work with a lab to test the product to determine how long an operation can safely hold it. ©2014 Foodservice Equipment & Supplies
- 19. Cook-Chill Considerations Food Safety It’s all about good food handling practices. Buy the right product and store it correctly. Maintain proper temperatures in the processing area. Understand and monitor time and temperature relationships. Personal hygiene means dressing for food safety success. ©2014 Foodservice Equipment & Supplies
- 20. Cook-Chill Considerations Food Safety It’s all about the process. Know when you need to verify temperature and record the results. Lab test the product to ensure you are on the right path. Following these steps consistently can make cook chill safer than cook serve. ©2014 Foodservice Equipment & Supplies
- 21. The Cook-Chill Process How to Equip a Cook-Chill Operation: •Review current and future menus •Document volume •Analyze cooking methods and equipment for each menu item •Determine the chilling method ©2014 Foodservice Equipment & Supplies
- 22. The Cook-Chill Process Volume and Product Drive the Process •Cook to a food-safe temperature. •Seal the storage containers air tight. •Hold product at or slightly above freezing. •Bring back to a food-safe serving temp. •Dispose of leftovers. ©2014 Foodservice Equipment & Supplies
- 23. The Cook-Chill Process Space Considerations •Equipment may require less space than you think. •Know your health department regulations; they can impact placement. •Inventory planning can be a bigger issue than space allocation. ©2014 Foodservice Equipment & Supplies
- 24. The Cook-Chill Process Managing Inventory •Develop a process for rotating product and record keeping. •Larger operations have flow racks. •You must date everything. ©2014 Foodservice Equipment & Supplies
- 25. The Cook-Chill Process Educational Requirements •Chefs’ learning curve includes adjusting recipes and developing an HAACP plan. •Various training options out there. •Overall, not too much training is required and you can do a lot in a short period of time. ©2014 Foodservice Equipment & Supplies
- 26. The Cook-Chill Process Key Points to Consider Understand the return on investment. You need to be all-in and think through the process. Fully integrate the process and understand the science behind it.
- 27. Questions from the Audience ©2014 Foodservice Equipment & Supplies
- 28. Closing Thoughts Paul Hysen’s: Become knowledgeable of the process and its limitations. Visit other cook-chill operations to see what works.
- 29. Closing Thoughts Connie’s Advice: Network with others and learn from their experiences. Think about today’s menu and what you might add in the future and plan accordingly.
- 30. Closing Thoughts Paul Mackesey’s Advice: Carefully select your staff. Invest the time and money to make sure equipment is well maintained and functions properly.
- 31. Thanks to Our Sponsors
- 33. Experts in Cook Chill Packaging & Equipment Processing Equipment • • • • • • Steam-Jacketed Kettles Tumble Chillers Jet Cook Systems Cook Quench Chill Systems Sous Vide Systems Recipe Management Software Food Packaging & Accessories • • • • • • Cook Chill Bags Cook Tank Bags Sous Vide Packaging Box Liners Ring Stands Heat Sealers / Clippers plascongroup.com | 888.584.4422
- 34. ThermalRite’s CypenVac™ Technology Honored with Kitchen Innovations® 2014 Award presented by the National Restaurant Association, Restaurant Hotel-Motel Show® The Secret’s in the Wall! ThermalRite’s CypenVac™ Technology , offered on its blast chillers and freezers, can reduce energy consumption by up to 43%! Faster Cooling – Safer Eating! ThermalRite Blast Chillers can help comply with HACCP guidelines – cool cooked food faster than other units available (straight from oven to chiller) …from+194°F to +37°F in just 90 minutes! Visit Thermalrite.com . Ask us for more information!
- 35. Future Webcast Ideas We are listening: Send your ideas for future webcasts to: Joe Carbonara joe@zoombagroup.com ©2012 Foodservice Equipment & Supplies
- 36. Keep in Touch Visit FE&S online at: www.fesmag.com Follow us on Twitter: @FESmagazine, @FES_Editor ©2012 Foodservice Equipment & Supplies
Notes de l'éditeur
- .
- From high-volume, central production to fully-plated banquet-style meals, a properly run Cook-Chill program can do wonders for the way your kitchen runs. Alto-Shaam’s integrated Combitherm, Quickchiller and Mobile Warming equipment provides the Cook/Chill solutions you need to succeed.
- Plascon Food Solutions has the packaging, equipment and expertise to help implement a new cook-chill system or improve efficiencies in your current operation. Additionally, Plascon offers unique patented technologies such as the Jet Cook System that dramatically reduces cooking time while improving the taste and texture of foods and recipe management systems to improve consistency and product traceability.
- ThermalRite’s CypenVac Technology is a winner of the Kitchen Innovations 2014 Award The Secret’s in the Wall! ThermalRite’s CypenVac Technology can reduce energy consumption by up to 43%! It can also cool cooked food faster than in other units available (straight from oven to chiller).
- JC: In your own words, define cook chill. PH: Cook chill is an advanced processing technique where by product is prepared under certain specified conditions for a later time. It got its start back in the 60s and 70s in Swedish hospitals, where they were using central processing and boil in the bag techniques. Cornell picked up on this and realized this approach could help operations better use their labor during slower traffic periods. You could produce product in advance and store it. And Cornell called it ready foods. A lot of this was economically driven as operators tried to understand how to better use their labor. Basically cook chill came from the foodservice industry’s desire to improve efficiency.
- PM: It’s a form of advanced food prep where no direct link exists between cooking and serving. In between cooking and serving, there is a period of holding that could last one day or weeks. This could be something as simple as a school preparing multiple days’ worth of a menu item it offers on a daily basis. Staff prepares enough for a week and then re-heats it as needed. Small restaurants can use it with sauces and soups.
- JC: What are the advantages of going to cook chill? CD adds: Allowing operators to offer more variety is a big driver. Instead of producing multiple soups on a daily basis, they are able to use their soup inventory. Many operators buying seasonal and local products. They get a truckload of tomatoes in season and need to be able to process it in a timely manner. Cook chill can help with that. Quality control. For some operators that’s more important than labor costs, particularly with quality ingredients. It is easier to control the quality of one batch instead of four. It can help with food waste, too. Because you reheat only what you need, cook chill can help prevent over production.
- PH: Other advantages to working with cook chill include: Efficiency in production: instead of small quantities, you can make larger batches without it taking more effort. So the incremental labor involved is not proportional to the size of the batch you are producing. Quality control: If I am producing in larger quantities I can devote more time to the oversight process, including weighing, scaling, etc. It’s easier to control the quality of one batch as opposed to four. Cost reduction: Less labor but more quantity. Waste factor is reduced, too. Product has longer shelf life and because I am not producing for immediate use, I don’t have to be as accurate in my forecasting. I am producing to inventory instead of a demand point, which requires me to be more accurate. Other benefits include it can help operators address storage/space issues and deal with peak traffic better PM: Cost savings: Following up on what Paul H., said, through centralized production, operators might be able to go to a heat and serve operation on the weekend, reducing need for skilled labor. Consistency: Gives you tighter control over how it’s stored, prepared, etc. Operators might have different skill levels from one location to the next, so product quality may be off occasionally. What might be runny at one place could be dry at the next. It impacts food costs because the operation is not getting same yield or portion control from one location to the next. And it impacts food safety because you don’t know that it was prepared without being compromised. Cook chill allows operators to prepare food under the tightest controls and they can verify aspects of the production.
- What’s driving the interest in cook chill? CD: There is a renewed interest because of all the advantages it offers for increased variety, improved quality, reduced waste, and efficient use of labor. Why operators are interested varies by segment but all segments are exploring this, including the educational market, correctional and more. Colleges are exploring cook chill as a means to take greater advantage of more locally sourced and seasonal produce. Some states are implementing local purchasing requirements and foodservice operators from various segments are looking at this as a way to up their percentages of local procurement. For K-12 there are government nutritional requirements kicking in that regulate sodium and fat levels, for example. Cook chill makes it easier for operators to manage these requirements without a lot of skilled labor at each outlet. In healthcare, patient room service operations are often based on restaurant style menus that can be supported by cook-chill inventories. B&I typically serves 10-meals per week and may use cook chill to produce stocks or the mother sauces Paul mentioned. It’s not just for one type of operator; cook chill can be a supplemental production method system for many applications.
- What kind of food is suitable for cook-chill? PM: It has to be something by its nature that an operator can cook to its proper temperature and then chill it quickly to safely hold the food. Salads are not a good fit. But a casserole could be good fit. Or a kettle product, like a soup, sauce or even stew or chili. Meat items can be good, too, if you can cool them quickly after cooking them to temperature. With cook chill operators can work with foods that have different types and textures of products. Even different flavor profiles.
- PH: Understand the sanitation questions that might be involved. You are now storing/holding product for some period of time. This introduces some challenges that might not be present in a cook and serve operation. Know what aspects of your menu are suitable for cook chill. It’s for certain applications that will enhance or at least maintain product quality, not degrade. Examples of what to do: soups, sauces, mother sauces. Take a white sauce, for example, and make it into a cheese sauce or chicken gravy right before serving it. Take a basic BBQ sauce you can make it western or Hawaiian by adding certain spices later. Modify your recipes: you may need to modify your starch or products can become a little watery. A lot of this depends on a how long your plan to hold it. Spices intend to intensify the longer you hold a product. The type of noodle you use, might want a different consistency that won’t break down. Rice, might want one that won’t make it mushy when cooling it with a tumble chiller. May want to work with menu development consultants. They understand what goes into transitioning to a cook chill operation. (Research chefs association, food technologists) The operation needs to be able to chill that product very quickly. Can’t let it air cool. This allows the products to transition through the danger zone of 45 degrees to 145 degrees quickly. Operators will need specific equipment to help with that. If I am going to hold it for a couple of days, the process need not be that sophisticated. If holding longer, then need it to be more sophisticated.
- That brings up a great, point. How long can an operator expect to be able to hold a product prepared using cook chill? PM: The quickness of the chilling is in direct proportion to the shelf life you get. Operators do not necessarily need a sophisticated, large system. It can be a simple system. But as the volume grows and the length of holding grows the system needs to be more sophisticated In the case of soup or sauce (small amounts) an ice wand or paddle might be a good use. And continuing to stir it to bring the product down from the pasteurizing temp to the holding temp in the desired time.
- CD: It depends on the product. For most items Maximum holding time is about four weeks. Some products can be frozen to extend shelf life, but remember Freezing changes texture and spices. Some get it into safe zone fast and then send to freezer, which can increase holding time. The best way to determine product shelf life is to work with a lab to test the product over time to ensure there is no bacteria or pathogens. And to see the growth of any hazardous pathogens over the holding time.
- Connie brings up a good point: food safety. How does cook chill support an operation’s food safety program? PM: It’s all based on good food handling practices. There’s nothing in a cook chill process that would not be part of standard food prep and holding. You are keeping cold food cold and holding it to a specific temp until it’s time to cook it. PH: Agrees with Paul M and adds: It starts with buying the right product. Know the specifications for the product and be diligent in inspecting it when it arrives in the back door. Make sure it holds the right temp from the time it hits the back dock through cooking/prep to when you use it. If you don’t start with a wholesome product it is not going to get better from there. Inspect the product as it comes in. Often we see an unskilled person out on the dock receiving product. Or many large institutions will have the loading/receiving dock a considerable distance from the kitchen, which means someone that’s not as knowledgeable is inspecting the product. The temp of the processing area: we have accepted for years that butcher shops should be refrigerated. It takes a leap of faith, though, to get people to undertstand production areas should be refrigerated, unless we are making hot food. We need better control over temperatures. There are a lot of times where we are blending ingredients. The fresh produce is in now starting to embrace that. Personal hygiene: employees should be gowned, including hairnets. Larger scale operations could include footware and foot baths. The larger the facility the more USDA-like procedures you want to apply because you are keeping the product for longer and exposing it to a much larger audience. Understand and monitor your time and temp relationships. Need to get it up to temp in the right time frame. Maintaining temp in the refrigerators and freezers is important, too.
- PM: It’s a process. Once you develop that process you need to follow it and there are critical control points in there where you will need to verify temperature. Product at the right temp when you pump and at the right temp when you bring it out of the water bath. So you monitor the time and temp throughout the process and record the results each and every time. Lab testing process: advocates you send it to an independent lab, which charts the individual growth plates for that product. That independent verification can come to your defense if someone claims there is a food borne illness. Once you know that process is safe and sound, you pick intermittent ones to verify. It can be much safer than a cook serve process.
- How do I decide what we need to equip this? CD: Review your menus; identify today’s products that are suitable, consider tomorrow’s products and document your volume. Analyze cooking equipment and cooling method for each component of the menu.. Liquid items can be produced in kettles or tilt skillets and pumped into bags for cooling. Bagged products can be most efficiently chilled in a tank with water and ice. Cooling can also useblast chillers for panned items. Cook chill tank allows product to be cooked and chilled in bags: The cooling tank has a steam line that allows you to bag the product with seasoning, etc. and throw it in the cook tank, turn it on to cook mode the food cooks to pre-determined temp. Tank drains and refills with ice water to cool the food. (Place a probe in the food) Products range from meats to rice pilaf.
- Walk the audience through the cook chill process, meaning what equipment is necessary, menu and space implications, inventory management, staff training and so forth. PM: Volume and product will drive the process. Start with cooking the product to a food-safe temp. That way when you place it in the holding mechanism it pasteurizes that storage vessel. Need to seal air tight. Can be a manual process where you take the hot product and deposit into a bag or some other container. Next piece, is you have to be able to seal it so it’s air tight. Reduced oxygen packaging. Open container with an open lid does not work. Hold it at or slightly above freezing Bring it to proper, safe food temperature and serve it or dispose of it. Tomato type products, you can easily get a month out of it. There are no leftovers in this process. Once you re-therm that product you need to consume it or dispose it.
- Does implementing a cook chill system require a large space commitment? CD: Not necessarily for the cooking equipment Space for kettles and tilt skillets may be less than you think. Remember you’re able to cook and packages multiple products over a shift.. Some health depts. making you put it in a separate area for sanitation, so be aware of the regulations for your area. Inventory planning is usually a bigger issue in allocating space. to hold/bank the food
- How do operators manage the inventory they are now creating? PH: This can be as simple as a spreadsheet that records what you made and label and date the bags. Larger operations can have flow racks to help manage a better in and out process. Dating is a common activity and this process is no exception. You need to have a process for rotating product and a record keeping process. And it is incumbent upon the managers to develop and work the process.
- Is there a lot of staff training and education involved? CD: At the chef level, there is an learning curve at the outset to adjust recipes and set up a sound HACCP plan. There are good resources available to assist with that. Networking with other cook chill operators is another approach to get started. Manufacturers are excellent resourcess for training staff to use and maintain the equipment. Depends on the products you plan to cook. Some require modified food starches. Good network of support out there, too, that can help train you. Does not take a lot of training. Trained chefs have the wherewithal to run this system You can do a lot of cycles in one day.
- What are some common mistakes to avoid? CD: Expecting an immediate return on investment. It will take more than a year for an operation to get a return on its investment. Analyze the volume and how the operation will use it. Then develop a budget. Even if you use sophisticated equipment, you will be able to get better use of your labor. And after a week’s worth of training you should be ready to roll. Has to be well thought out and you need to be all in. Be prepared to follow the methodology that keeps the food safe. Lack of integration. Don’t understand the science behind it. So you can’t use your same recipes. May need to alter them. Think trhough to the point that you understand how you are bringing it back up to temp and plating it.
- PH: Become knowledgeable of the process and what its limitations are to determine what’s appropriate for your business. Visit other cook chill operations to see what works.
- CD: That’s a great point, Paul. Network with others in your industry and learn from their experience and advice. Don’t only think about today’s menu. What could you do in the future that you are not doing today? And size accordingly.
- Selection of staff: If they appreciate the necessity for following processes and procedures are good fits. If you are a person that changes on the fly, you will not be a good fit. Be conscious of the items you will prepare. Some won’t fit well within this process. Invest the time and money to make sure the equipment is well maintained and can function properly. Breakdowns can be costly and impact the process. So make sure you get good equipment and maintain it.
- "From high volume, central production to fully plated banquet style meals, a properly run Cook-Chill program can do wonders for the way your kitchen runs. Alto-Shaam’s integrated Combitherm, Quickchiller and Mobile Warming equipment provides the Cook/Chill solutions you need to succeed.”
- Plascon Food Solutions has the packaging, equipment and expertise to help implement a new cook-chill system or improve efficiencies in your current operation. Additionally, Plascon offers unique patented technologies such as the Jet Cook System that dramatically reduces cooking time while improving the taste and texture of foods and recipe management systems to improve consistency and product traceability.
- ThermalRite’s CypenVac Technology is a winner of the Kitchen Innovations 2014 Award The Secret’s in the Wall! ThermalRite’s CypenVac Technology can reduce energy consumption by up to 43%! It can also cool cooked food faster than in other units available (straight from oven to chiller).