Volume of food varies from one operation to the next. Please contact Cleveland Range for assistance.
COOK CHILL PRODUCTION AREA
HA-MKDL-200-CC-T, 200 gallon tilting horizontal agitator mixing kettle is by far the most efficient kettle for cooking while mixing both heavy and delicate ingredients and is used for hands-free mixing of kettle items while allowing staff to multi-task. Operator can easily set the speed of the kettle agitator and temperature of the kettle. Many customers prefer the ease of working with a tilting kettle for loading ingredients, cleaning, and for producing productions that cannot be pumped.
HA-MKDL-100-CC, 100 gallon stationary horizontal agitator mixing kettle is by far the most efficient kettle for cooking while mixing both heavy and delicate ingredients and is used for hands-free mixing of kettle items while allowing staff to multi-task. Operator can easily set the speed of the kettle agitator and temperature of the kettle. Consider a tilting kettle model HA-MKDL-100-CC-T for increased versatility. Many customers prefer the ease of working with a tilting kettle for loading ingredients, cleaning, and for producing productions that cannot be pumped.
P-KDL-100-CC, 100 gallon Pasta Kettle in conjunction with perforated stainless steel pasta basket can be used for cooking pasta, bones for stock, dried beans, or other foods that require cooking and straining. Large overflow drains and cold water injection system allow flushing water through pasta to cool and rinse.
HA-DE-CC, Dual Kettle Control Panel for both Horizontal Agitator Kettles, can be located within inches or several feet from the kettles. Located in one cabinet, each Control Panel contains separate controls for automatic or manual cooking and cooling, digital temperature and water read outs, chart recorder for recording the temperature of the product during a 24 hour period of food production, water meter (please indicate the need for hot or cold water or both), agitator speed. Options include Computer Data port, hot/cold water, stainless steel control cover, additional buttons for safety or convenience of the operator.
P-SR-CC, Single Kettle Control Panel for the Pasta Kettle, can be located within inches or several feet from the kettles. Control Panel contains controls for cooking and cooling, a chart recorder for recording the temperature of the product during a 24 hour period of food production and water meter (please indicate the need for hot or cold water or both), water injection. Options include Computer Data port, hot/cold water, stainless steel control cover, additional buttons for ease of operation.
MFS, Metering Filling Station is used for quickly pumping hot or cold products out of the kettle into bags or, when necessary, steamtable pans. Order Casing clipper to close bags.
CT-1000, Cook Tank holds approximately 1000 lbs. of vacuum packaged products.
P-TC-220, Tumble Chiller is used for chilling up to 220 gallons of bagged kettle products in an average of 45 minutes. Ice cold water can be stored in the water re-use tank in between batches.
CVW, Vacuum Clipper (new model number CVW. Also see model CV-E-8065) is used for vacuum bagging cook tank products prior to cooking. Optional casters allow operator to move vacuum clipper when not in use.
CVY-220, Casing Conveyor carries cook chill bags into the Tumble Chiller.
CH-H-101-M, one ton motorized hoist for lifting the Pasta Basket. Please ask for stainless steel hook and chain. Options include festoon cable, cable reel, remote control.
IWCP, Ice Water Control Panel is needed for checking operation of ice water system. Other water cooling options may be available depending upon the size or type of operation. Please contact Cleveland Range LLC Cook Chill for assistance.
PB-K-100 and PB-D-100, 100 gallon Pasta Basket and Dolly for use with P-KDL-100-CC. Please note that the kettle agitator arm can be removed so that the other kettle can be used for pasta cooking. The Pasta Basket is perforated for easy cooking and draining of pasta stock bones, beans and other items. The Basket can be hoisted out of the kettle and into the Pasta Basket Dolly for transporting the Basket.
SUPPORT SYSTEM – MECHANICAL AREA
IBC-250, 25,000 pound Ice Builder holds cold water. Coils in the Ice Builder build up ice and keep the water icy cold. This ice water can be piped to the tumble chiller and cook tank for cooling bagged products. Ice water can also aid in kettle cold food production.
BLH4000C6, air cooled condensing unit runs Freon through the coils in the Ice Builder
CAS-7.5, Compressed Air System is used to operate the air piston on the Kettle, MFS, clipper, and Vacuum Clipper.
ADA-40,Air Dryer is required on CAS-7.5.
IBPP, Ice Builder Pump Package circulates ice water from the ice builder to the heat exchangers on the tumble chiller, kettles, and cook tank. Please note that this must be sized by a Mechanical Engineer due to differences in equipment and building layouts.
GFB-30, Gas Fired Boiler is used for creating steam for the kettles and cook tank. If other steam equipment is planned for the facility, it is recommended that boiler capacity be recalculated.
Cook Chill Return on Ivestment:
Return on investment (ROI) for larger cook chills system like this may take 2 to 4 years, shorter or longer, depending upon how aggressively the owner or operator run the system. This may include changing from a 7 day production week to 5 day week (please contact Cleveland Range LLC Cook Chill for assistance and more information), cooking back-to-back batches, changes in purchasing and inventory parameters and other factors. Analyzing the ROI should include not just the cook chill food production but also the resulting savings in food, labor, in other parts of the operation such as retherming products, tray service, replacement of expensive convenience foods, changes in staff both in the centralized operation and the receiving facilities.
Basic Principals of Cook Chill:
Cleveland Range Cook Chill is defined as an Advance Food Production System where food is cooked in Kettles, quickly pumped into bags and rapidly chilled in an ice water bath to 40 degrees or less in an average of 45 minutes to meet the USDA Guidelines. Additionally, meats that are vacuum packaged and cooked through the Cook Tank Process meet the USDA Guidelines of chilling in less than 6 hours. Bagged menu items can be easily transported and heated in the bags or re-portioned into serving containers for sale or tray rethermalization.
Typically a food service facility has a menu where 40 to 60% of the menu items can be cooked in steam kettles. Using a mixing kettle improves cooking time and reduces labor while maintaining the high quality of the kettle items such as soups, sauces, stews, casseroles, pie fillings, salad dressings and many more items.
Cook Tank Production:
Cook Tank Production: While somewhat unknown to many food service operators, cook tanks produce large volumes of food from 300 to 2000 lbs per batch while providing huge savings. An example of a cook tank food is deli turkey. Cleveland Cook Chill Operators can produce their own deli turkey and other roasts. Some advantages are:1. Reduced shrinkage of the finished turkey from 25% shrinkage to less than 10% shrinkage when compared to an oven cooked turkey.2. Improved slicing and reduced crumbling or tearing of the meat because it is more moist than an oven product and can be sliced cold while retaining its shape.3. Fast ROI, (return on investment) resulting from reduced losses noted above and ease of handling.4. Consistently high quality.Contact Cleveland Range LLC Cook Chill for more information or assistance.
Since Cook Chill Advanced Food Production Systems are unique, a Factory Support package is recommended to provide drawings, installation, technical and operations support from the beginning and throughout the project. Cleveland Range, LLC is known to provide the most thorough Factory Support to cook chill customers. Please see section on Cleveland Range LLC Factory Support for Cook Chill.