An Introduction to:
Cook Chill Advanced
Food Production Systems
Cook / Chill Systems
It's all about offering
more choices & providing better solutions.
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Cook Chill
Overview
COOK CHILL FOOD PRODUCTION is a process of cooking food to a "just done state", packaging
in tough oxygen impervious casing at pasteurization temperature, and then rapid chilling to 40°F in less
than one hour. This enables the "Fresh Product", which has not suffered structural degradation via freezing
or high temperature canning to be stored in a refrigerated Food Bank for up to 45 days (depending on
product).
The product can then be:
A/ Rethermalized in its' original casings or in pans at the production location.
B/ Transported cold to satellite locations to reheat and serve in its' original casings or in pans.
With the addition of ancillary support equipment (including conventional production and refrigeration equipment) a
fully integrated, synergistic, operational advanced food production system is ensured.
COOK CHILL PRODUCTION ADVANTAGES
The main difference between Cook Chill and Cook Serve operations is that Cook Chill production fills an inventory or
"Food Bank" for future use, and Cook Serve is intended for immediate use.
• Having a pre-stocked inventory eliminates the peaks and valleys associated with Cook Serve operations.
• Production time is reduced by approximately 45%. Menu items for a seven day around the clock facility can now
be produced in five/eight hour shifts per week.
• Production can be centralized for operations where food is distributed to off-site locations.
• Space allocation for production is usually reduced by employing high volume equipment.
• Quality and consistency of the finished product is improved by the use of controlled production techniques.
CONCLUSION
Cook Chill is not a mystical cooking system. Virtually every step in conventional food production is repeated
during the Cook Chill cooking cycle with exacting standards. The key elements are controlled cooking and rapid
chilling of the product thus eliminating degradation to food quality caused by high temperature holding or
freezing.
The result of a Cook Chill system is consistent food quality, with optimal color, texture, moisture content and
nutritional value.
Menu
Food for Thought
Cook Chill Food Preparation offers flexibility for
a wide array of menu styles. Basically any style
menu, excluding short-order grilled foods, can be
produced and served in a Cook Chill System. Due to
efficiencies in production and a chilled inventory, a
wider variety of daily choices can be made available
to clients with both cycle and restaurant style menus.
Cook Tank items are usually thought of as meat items only.
Here are a few more suggestions:
• Spanish Rice • Potatoes for Hash Browns • Buttered Rice • Beets in Orange
Sauce • Candied Sweet Potatoes • Sweet N' Sour Pork • Harvard Beets •
Parsley Buttered Potatoes • Meat Loaf • Meat Balls • Salisbury Steak • Baked
Chicken Breasts • Quartered Chicken for BBQ • Baked Ham, slices or whole •
Corned Beef • Short Ribs • Pork Chops • Pot Roast • Roast Beef • Roast Turkey
Food quality can actually be
improved with conversion to a
Cook Chill System.
• Rice Pilaf • Swiss Steak • BBQ Ribs
With conventional systems, food
is subject to high temperatures
for long periods of time resulting
in a loss of moisture, color and
texture. Consequently, quality at
the
point
of
service
is
significantly compromised and
often inconsistent.
Any liquid product, or product
that will flow when hot can be
pumped by the Cleveland
Metering Filling Station.
Kettle Products
Sauces & Gravies- An Endless Variety.
• Cream Sauce • Cheese Sauce • Au Jus •
Tomato - Lasagna Marinara, Pizza &
Spaghetti Sauces • Enchilada Sauce •
With a Cook Chill System, the
opportunity exists to serve
consistently high quality food
products by:
Jardiniere Sauce • Cheese Sauce - used
with Au Gratin Vegetables • Mustard Sauce
- Chinese • Orange Sauce for Roast Duck •
Chili Con Quesa • Nacho Sauce • Barbecue
Sauce • Cream Sauce for Vegetables •
1. Standardization of recipes and
batch preparation of products.
Raisin Sauce • Beef, Chicken, Turkey, Pork,
or Veal Gravy • Giblet Gravy • Cream Gravy
2. Cooking only to desired
doneness and rapidly chilling to
stop the cooking process.
• Country Gravy
Cold Products • Fruitbread & Muffin Batters • Salad
3. Rethermalization of products prior
to service, avoiding hot holding for
extended periods of time.
Dressings • Salads - Potato, Macaroni, or
Meat
Chinese Dishes - A few to consider.
Cook Tank Products
Food quality can actually be improved with
conversion to a Cook Chill System.
Because the meat is cooked
slowly, at a low temperature, even the least tender items are
made tender. There is an average of 25% less shrinkage
due to no evaporative and drip loss producing a more juicy
product.
The cooking skill required is in recipe development
and determining sauces, etc.. This type of cooking is
a controlled, even, slow, water bath method, with no
danger of over-cooking. The cook does not have to
remember to turn the pan, take the product out of the
oven or determine doneness. This means the
"guesswork" is taken out of the process, which results
in fewer mistakes and less waste.
• Cashew Chicken • Beef or Chicken Chow
Mein • Beef and Broccoli • Ginger Beef
Mexican Dishes - Always the favorites.
• Refried Beans • Taco Meat • Enchilada Sauce • Nacho Cheese Sauce
Soups - Here is where the real efficiency is. Create your own specialized recipe.
• Broth Soups - Beef or Chicken Noodle, Beef or Chicken Rice, Won Ton,
Alphabet Soup, Beef Barley, French Onion, English Barley • Cream Soups Tomato, Mushroom, Asparagus, Broccoli, Carrot, Chicken, Potato • Hearty
Chowders & Soups - Corn Vegetable, Minestrone, Navy Bean, Clam Chowder,
Split Pea
Dishes to Fit Everyone's Palate - Or convert your own favorite recipe.
• Pork & Beans • Barbecued Beef • Beef Tips in Mushroom Gravy • Beef Cubes
in Brown Sauce • Beef Goulash • Beef & Macaroni Casserole • Macaroni &
Cheese • Beef Stew • Beef Stroganoff • Pot Pie Filling • Chili Con Carne • Stews
After the meat is cooked and chilled it is still protected by
the casing and therefore as it is held in the very low
temperature refrigerator it does not lose or change flavor
and it maintains its' high quality.
of all kinds • Curry dishes of all kinds • Sloppy Joe • Stewed Tomatoes • Turkey
Ala King • Whipped Potatoes • Tuna Noodle Casserole
2. Bulk Purchasing
& Pre-Prep
28°F
to
32°F
Cook/Chill Recipes
7.
Refrigerated
Storage
4. Non Pumpable Food Preparation
• Health Care
Operations
• School Food Service
• College and
University
Food Service
• Restaurant Chains
• Correctional Food
Service
lb
• Military Food
Service
0
.
5
45
0
Kg.
50 lb. x 2 oz.
22 kg. z 50 g.
35
5
• Supermarkets
& Delis
10
20
40
22
15
10
15
30
20
25
• In Plant Service
• Transportation Airlines, Railway
1. Central Planning/
Scheduling
• Recreation - Hotels,
Resorts, Amusement
Parks
3. Pumpable Food Preparation
5. Transfer & Packaging
6. Tumble Chilling
8. Rethermalization & Serving
Planning & Food Preparation
2. Bulk Purchasing & Pre-Prep
1. Central Planning/ Scheduling
To suit the operators volume and menu requirements, Cook Chill products are
prepared to fill an inventory or food bank well in advance of serving.
Production for a seven day around the clock facility is normally handled in
five/eight hour shifts per week instead of the usual seven/twelve hour shifts per
week. Skilled and unskilled labor is more efficiently utilized.
Recipes are standardized for batch preparation guaranteeing consistent high quality
food product with optimal color, texture, moisture content and nutritional value.
Volume purchasing and receiving dramatically reduces ingredient and
handling costs, and allows for a five day receiving schedule.
As per scheduled recipes, ingredients are centrally prepared in advance.
Ingredient quality and recipe consistency are maintained to extremely high
standards.
Cooking, Packaging & Chilling
3. Pumpable Food Preparation
5. Transfer & Packaging
Cook Chill steam jacketed Kettles are designed and equipped for cooking a
variety of pumpable food products with qualities ranging from chunky to smooth.
Horizontal, Vertical (Sweep Fold®), and Inclined Mixer Kettles are available for
mixing ingredients, maintaining product consistency and eliminating
burning/scorching.
Temperature controls, temperature chart recorders and automatic water cooling
ensure the product is consistently cooked and cooled to your specifications.
Product Metering Filling Stations pump the cooked foods while still hot
(180°F), from Mixer Kettles and accurately meter them into flexible casings.
The clipper and label dispenser are conveniently mounted on the cross bar
allowing the operator to seal, label and trim the filled casing in one swift
motion.
The air operated piston pump has infinitely variable volume adjustment and a
2" delivery system allowing the pumping of virtually any product that will flow.
4. Non Pumpable Food Preparation
6. Tumble Chilling
Cook Chill Tanks are designed for water bath cooking of vacuum packaged
meats, and other packaged food items.
Low temperature cooking reduces shrinkage, increases tenderness and
retains natural juices and flavor.
Upon reaching the desired temperature, hot water is automatically
exchanged for ice water, efficiently reducing food temperature below 40°F in
the fastest possible time. Programmable Time/Temperature controls allow for
unattended overnight cooking.
The Tumble Chiller rapidly reduces the temperature of the filled casings with
a gentle tumble action in recirculating potable chilled water without product
damage.
The casings are loaded through an entry chute by hand or conveyor. Fully
automated controls assure correct chilling in the fastest possible time for
maximum refrigerated storage life.
Blast Chillers are also available to provide chilling for short term storage of
products not compatible with water bath chilling methods.
Storage & Rethermalization
7. Refrigerated Storage
8. Rethermalization & Serving
The prepared and chilled foods are safely stored in low temperature walk-in
refrigerators at a temperature of 28°F to 32°F.
Cook Chill food preparation allows for a safe refrigerated storage life of up to
45 days (depending on product). Menu items are now available for use on site,
or to be shipped via refrigerated trucks or holding cabinets to remote serving
points or satellite locations.
Not freezing the foods boasts many benefits; dramatic energy savings, the
freshly prepared qualities of food are maintained, and the nutritional attributes
of food are not lost.
A wide variety of methods and equipment are available to heat the
preprepared food to a safe serving temperature.
Convection Steamers, Kettles, Combination Steamer/Ovens, Tilting Skillets
and other conventional cooking equipment can be used to finish the product.
Kettles and Skillets are used for hot water bath heating of multiple casings.
Convection Steamers and Combination Steamer/Ovens can be used for
heating multiple casings or product emptied on to 2 1/2" solid pans.
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When you select a Cleveland
System
you are assured of receiving a completely integrated
system designed to meet you production goals.
Our commitment to technical and operational support
guarantees maximum utilization and satisfaction.
Cooking, Packaging & Chilling
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Controls the functions and
features of the Mixer Kettles and
the Pasta Kettles.
Cook Chill Tanks
Packages a
variety of products
in random sizes
and widths for
cooking in a Cook
Chill Tank.
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Single & Double
Control Centers
Cook Chill Mixer Kettles - Horizontal, Vertical & Inclined
Three styles of mixing kettles are available for your consideration. Each are capable
of cooking and mixing a variety of products with some or all or the following qualities:
heavy, delicate, frozen, crisp, chunky, smooth, hot or cold. All have been
successfully used in the food production and processing industry for many years.
Designed to pump
cooked foods from Mixer
Kettles and accurately
meter them into casings.
The 2" discharge allows for
the pumping of chunky
products without damage.
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Vacuum
Packaging
Systems
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Metering Filling
Station
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Designed for water bath cooking of
vacuum packaged meats and other
items. Low temperature cooking
reduces shrinkage, increases
tenderness and retains natural juices
and flavor. When the cooking process
is complete, hot water is exchanged
for ice water for rapid cooling.
Pasta Kettles & Baskets
Designed specifically for cooking
pasta and pasta-like products. The
Kettle is equipped with a large
overflow drain for rinsing the product.
Tumble Chiller/Cook Tank
Combination Units
Saves valuable kitchen space by
combining two important functions into
one piece of equipment. During the
day the Tumble Chilling method is
used to cool Kettle cooked products.
During the night the combination unit
can be utilized as Cook Chill Tank.
Tumble Chillers
A mechanical rotating
machine used to reduce
temperature of the casings
with a gentle tumbling
action in recirculating ice
water. Casings are loaded
through the entry chute by
hand or conveyor.
Support Equipment
Steam Boilers
Necessary whenever food
processing equipment requires
direct steam for operation.
Available in electrically heated,
gas or oil fired.
Condensing Units Air & Water Cooled
Required for mechanical
refrigeration of water in the Ice
Builder by building ice around
the coils.
The Condensing Unit s
capacity should be sized,
based on building a full load of
ice within 16 hours.
Ice Builders
Designed to provide a
continuous supply of ice water
to Tumble Chillers, Cook Chill
Mixer Kettles, Cook Chill Tanks,
etc.. A pump circulates the ice
water, when required, through
heat exchangers located in the
Tumble Chillers, Cook Chill
Mixer Kettles, or Cook Chill
Tanks. Each Ice Builder can
economically build ice for up to
24 hours a day.
Compressed Air
Systems
Hoist Systems
A supply of compressed,
dry, clean air is required to
operate major components
used in Cook Chill Systems
(i.e. Tumble Chillers, Metering
Filling Stations, Clipper, the
Piston Valve on Mixer
Kettles). Compressed Air
Systems consist of an air
compressor and a
refrigerated air dryer.
Recommended for lifting and
transporting large and heavy
product loads from Cook Chill
Tanks, Pasta Kettles and
Cook/Chill Mixer Kettles.
Conveyors
Designed for automatically
transporting the Casing
packaged Food Products from
the Metering Filling Station into
the Tumble Chiller.
Rethermalization
Kettles
Available in over 60 different models, all
steam jacketed to cook quickly and evenly
without sticking, burning or scorching.
Powered by either electric, gas or direct
steam sources.
Heat water bath to 190°F and place
casings into the Kettle for rethermalization.
Gently stir with a paddle to move the
product in the casing for fast and even
heat-up time to 165°F.
Convection Steamers
Cleveland Convection Steamers offer a
creative concept for preparing high
volumes of a variety of food products at an
incredibly fast pace while maintaining a
very high quality standard.
To rethermalize products simply place
casing into 2 1/2" deep perforated pan and
heat to 165°F.
Combi-Oven Steamers
The most advanced family of
commercial cooking equipment available
today. Memory programmability stores
different recipes, making operation
simple and fast for the operator.
To rethermalize products simply place
casing into 2 1/2" deep perforated pan
and heat to 165°F.
Tilting Skillets
Cleveland Tilting Skillets are
designed for exceptional versatility
by functioning as a Griddle, Frying
Pan, Kettle, Braising Pan, Steamer or
a Bain-Marie.
Heat water bath to 190°F and place
casings into the Skillet for
rethermalization. Gently stir with a paddle
to move the product in the casing for fast
and even heat-up time to 165°F.
STEAMERS / COMBI-OVENS / KETTLES / BRAISING PANS / ROTISSERIES / COOK CHILL SYSTEMS
Ph: 1-800-338-2204 / Web: www.ClevelandRange.com / Email: Steam@ClevelandRange.com
Experts in Steam Cooking
Cook Chill System Support
PRE-SALES SUPPORT
Operation & Management Specialists are available for project &
menu evaluation to make recommendations for the facility
layout and equipment sizing.
Factory Engineers/Specialists are available to assist the food
service design consultant:
• Specific shop drawings are provided which include
dimensions, utility connection points, required clearances, etc.
• Typical Cook Chill Systems schematic drawings for piping &
wiring are provided.
• Factory Engineers can check the drawings for accuracy and
make recommendations for changes if required.
PRE-START-UP SUPPORT
Guidelines for Cook Chill recipe development and HACCP are
provided by our Operations Specialists/Registered Dietitians with
emphasis on recipe development for your specific operation.
Prior to installation of the equipment a Factory Specialist is
available to meet with the food service consultant and the
installer to inspect the job site and to review the installation
drawings with the installers.
After the installation has been completed:
• A Factory Specialist is available for inspection of both the
installation and operation of the equipment. Before the
installers leave the site recommendations for installation
changes are made if required. Calibration of the production
equipment is completed at this time.
• In-house maintenance personnel can be trained during startup, in the care of the equipment and preventative
maintenance.
• The Local Cleveland Authorized Maintenance and Repair
Agency will also be available for technical assistance. The local
agency will carry spare parts and is factory trained and
certified prior to start-up.
ACTUAL START-UP with food production and staff training
Training will be provided by our Operations Specialist with
emphasis on:
• Food Sanitation & Handling • Operation of the Equipment •
Recipe Implementation • Food Production
• HACCP and Quality Assurance Guidelines
SITE VISITS & FOLLOW-UP TRAINING can be scheduled to
review and reinforce information.
WARRANTY
All materials and workmanship is warranted for one complete
year.
CLEVELAND RANGE COOK CHILL ADVANCED FOOD
PRODUCTION SYSTEMS ARE
SUPPORTED BY:
• Operators Manuals • Administrative Procedure Manuals •
Service Manuals • Cook Chill Kettle recipes • Cook Tank recipes •
On-site training of the in-house maintenance personnel • Chilled
Food System Guideline Manual • AutoCad drawings • Operator
training and follow-up site visits
SOLUTIONS
Cleveland Range LLC. provides many of the operational solutions from Manitowoc, a global company dedicated to bringing
value to foodservice operators by equipping them with highly individualized real-world answers that enhance menus, service,
profits, and efficiency.
FINANCING
Manitowoc offers low-rate, fast-approval financing on equipment from Manitowoc brands and on other equipment when
purchased with Manitowoc brands. Preserve capital, simplify budgeting, and get the equipment you need today, from
Manitowoc Authorized Dealers with Manitowoc financing.
SERVICE
Cleveland Range LLC. products are backed nationwide by Manitowoc STAR Service. This network of certified service agents
provides fast response with factory-trained experts to assure your equipment will be fixed right the first time. Manitowoc STAR
service agents guarantee their work and use genuine OEM parts for best equipment performance and longer life.
To learn how Cleveland Range LLC. and other leading Enodis brands can equip you,
or to apply for financing, visit www.enodisusa.com, consult your dealer, or call 727-375-7010.
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