Cook-Chill Technology Chapter 15 (c) 2014 by John Wiley & Sons, Inc.

 Cook-chill is the process of cooking food in quantity and then rapidly chilling it.  Food isn’t frozen, but cooled rapidly so it passes quickly through the danger zone for bacteria growth.  After chilling, refrigerating food at proper temperature prolongs shelf life at least 5 days and up to 21 days.  Designed for controlling labor costs and turning foods out in quantity, often for multiple locations from a central commissary.  Uniformity of finished food product is an advantage, but also why some chefs think of cook- chill as “institutional.” Introduction to Cook-Chill (c) 2014 by John Wiley & Sons, Inc.

In this chapter, you will learn to:  Explain the uses, benefits and drawbacks of coo-chill technology.  Describe the cook-chill process, including recipe adaptation and food safety.  Identify the equipment used in the cook-chill process. Learning Objectives (c) 2014 by John Wiley & Sons, Inc.

 Food is made fresh and from scratch – then packaged and chilled quickly for later use instead of serving immediately.  Centralized production minimizes need for kitchen space, appliances, ventilation at more than one site.  Not restricted to large, high-production foodservice. Can be used for banquet, catering needs; safely storing extra portions.  Labor savings of 10% to 40%  Savings from bulk purchasing of raw ingredients  Greater menu flexibility  Ability to honor special needs and diet restrictions, because food is pre-portioned Why Use Cook-Chill? Cook-chill offers multiple advantages for a busy commercial kitchen (c) 2014 by John Wiley & Sons, Inc.

Why Use Cook-Chill? 5 More cook-chill advantages…  Greater food safety, with procedures and equipment designed to minimize temperature “danger zone” exposure  Simply having to reheat before serving leaves kitchen, wait staff time to focus on presentation, customer service.  Portion control is easier to achieve, reducing waste  A less stressful kitchen environment, as foods don’t have to be cooked to order  Overall increased profitability on multiple fronts: higher turnover rate; less cost for workers and kitchen space; less inventory must be stocked (c) 2014 by John Wiley & Sons, Inc.

Basic steps in a cook-chill system How Cook-Chill Works (c) 2014 by John Wiley & Sons, Inc. © John Wiley & Sons, Inc.

How Cook-Chill Works  The theory: Hot foods are cooled through the bacterial danger zone quickly and uniformly, then stored cold (or frozen) until reheating to be served. This requires:  More sophisticated refrigeration than a standard commercial walk-in or reach-in  Top-quality raw ingredients for the best possible final product  Safe, sanitary storage conditions – for raw ingredients and finished foods  Some modifications in prep work to ensure effective and uniform quick-chilling  Some recipe modifications to account for reactions of starches, spices, flavors to the cook-chill process (c) 2014 by John Wiley & Sons, Inc.

How Cook-Chill Works  The process: Cooking methods don’t change, but foods are handled differently after cooking to quick-chill them.  Special attention to core food temperatures is critical during cooking to destroy bacteria.  Cooked food is loaded into shallow, covered pans to promote faster cooling.  Foods with high liquid content may be stirred with special paddles filled with ice-water.  Foods are portioned depending on how they will be chilled.  Two types of chilling: Blast chilling and tumble chilling  Additional option: Cook and chill in same appliance with a cook-cool tank (c) 2014 by John Wiley & Sons, Inc.

Blast Chilling Blast chilling is for solid foods (not a lot of liquid content). Food in covered pans is placed on shelves inside chiller, or rolled in on a cart or rack. Powerful fans blast food with cold air to chill quickly. Operator can choose from multiple chilling modes, from “soft chill” (delicate) to “flash freeze” (brings food to 0º F.) Food can be chilled and held overnight if necessary. Wide range of sizes can produce from 18 to 400 pounds of food per load (c) 2014 by John Wiley & Sons, Inc. Courtesy of Alto-Shaam, Inc., Menomonee Falls, Wisconsin.

 In addition to obvious considerations – menu, cooking volume and how much space you have – consider:  Airflow – Velocity, direction and balance of air flowing to chill the food can dry it out or not chill evenly.  Reach-in or roll-in? Adjustable shelves are preferable for reach-ins. Roll-ins are for higher volume needs.  Compressor – As refrigerated units, only the smaller models have internal compressors. External requires more room for appliance and refrigeration lines.  Ability to freeze – Does it need to cool food, or freeze it? Cook-freeze systems use more energy, but are preferable for long-term food storage.  Compatibility – How does this chiller fit with the rest of your kitchen and product flow? Is there enough refrigerated space for the amount of product it will turn out? Buying a Blast Chiller (c) 2014 by John Wiley & Sons, Inc.

Tumble Chilling  A tumble chiller is more than a piece of equipment. It is part of a process to cool foods with high liquid content.  When done correctly, can double shelf life of foods compared to blast chilling.  Food is cooked in an agitator kettle, with mixing arm to keep contents suspended and well mixed as they are pumped into containers…  Or sent to a pump-fill station for pumping into flexible plastic tubes or casings; then sealed, weighed and labeled at a metering station.  Tubes are placed in tumble chiller, which gently kneads and chills them in a rotating drum of ice-cold water.  Cold water is supplied by a machine called an ice builder. (c) 2014 by John Wiley & Sons, Inc.

Tumble Chilling Equipment (c) 2014 by John Wiley & Sons, Inc. Courtesy of Groen, Unified Brands, Jackson, Mississippi.

Other Chilling Options  For small-volume needs, food may be chilled in ice- water bath. Lower the filled container into a larger container filled with ice and water.  Pre-chill large batches of food by stirring with hollow plastic paddles, filled with water and pre-frozen.  Use conduction shelves, filled with water and antifreeze that circulates through hollow shelf interiors to cool food quickly.  A cook-cool tank is appropriate for some types of uncooked foods in plastic casings.  In this sealed cabinet filled with wire racks, food is cooked by circulating hot water in the tank. Then, ice-cold water replaces the hot to begin the quick- chill process. (c) 2014 by John Wiley & Sons, Inc.

Storage and Distribution  The goals: Keep cook-chilled foods at a constant, safe temperature and prevent cross-contamination from other foods stored in close proximity.  Install dedicated reach-in or walk-in for cook-chilled products, with temperature monitor/alarm system.  Organize current walk-in to include a cook-chill area with separate conduction shelves.  Enforce strict labeling, storage and FIFO rules to ensure that foods stored the longest are used first.  Promptly use or discard food that reaches higher (41º F. to 50 º F.) temperatures unexpectedly.  Consider periodic laboratory safety testing of stored foods.  Select high-quality insulated containers for food being transported to serve at other sites.  Check food temperatures upon arrival at remote destination. (c) 2014 by John Wiley & Sons, Inc.

Rethermalization  Any cooking appliance can be used to bring cooled foods to correct serving temperatures – the key is to do it safely and without compromising food quality, appearance.  Retherm carts are for reheating and holding hot with “roaming” capability (hospitals, nursing homes).  Choose one that can switch from dry to moist heat.  Optional refrigerated compartment is handy.  Make sure it accommodates the type of dishes you want to use.  Check for size constraints, power requirements where cart will be used. Courtesy of Alto-Shaam, Inc., Menomonee Falls, Wisconsin. (c) 2014 by John Wiley & Sons, Inc.

Cleaning Cook-Chill Equipment  Agitator kettles must be cleaned, sanitized between uses, including fill lines.  Pumping stations must also be cleaned between uses.  Use bleach for sanitizing – thorough, clean-water rinsing is required.  Parts of this equipment – tumble chillers, agitator kettles – can be removed for separate cleaning. Use manufacturers’ recommendations for cleaning products.  Some parts, seals require lubrication with approved, food-grade grease before reinstalling. Cleaning tips for hard-working cook-chill systems (c) 2014 by John Wiley & Sons, Inc.