cook-chill production systems

by

®

Cook-Chillisarevolutionarywaytocreatemealsthatlookandtasteliketheywerefreshly

andindividuallyprepared…yetmayhavebeenproducedforhundredstothousandsatatime.

CapKold®isoneofthemarketleadersinCook-Chilltechnology.Withdedicationtoresearch

and development, CapKold continues to bring innovation to Cook-Chill, including new products and

enhancements.

THE COOK-CHILL PIONEER In the early 1970s, Groen and a major

packaging film manufacturer developed CapKold

– a food production, packaging and rapid chilling

system designed as a safe, economical alternative

to traditional cook-and-serve. Groen was the

first to apply volume food production techniques,

sophisticated control technology and the latest

packagingfilms to theCook-Chill concept. Today,

CapKold provides equipment systems that offer

cost-savingswhiledeliveringthefreshtasteand

qualityofjust-cookedfood.

CapKold kitchen (from left to right, shown above) - kettle control panel, (2) kettles, tumble chiller and pump-fill station

• Cooking,packagingandchilling

equipmentallowspreparationof

multipleportionsinasinglebatch;

• Sophisticatedsystemscontrol

equipmentandmonitorproduct

throughtheentireprocess;

• Combinationofplasticcasingsand

waterbathchillers

acceleratechillingand

deliversafe,extended,

refrigeratedshelflivesup

to30days.

Refrigerated food bank for storage up to 45 days

MATCHING FOOD PRODUCTION TO DEMAND The Cook-Chill concept was developed

asasolutiontotheage-oldproblemofmatching

food production to demand. It separates food

productionfromfoodservingbycreatinga“food

bank”orinventoryofpreparedproduct.Thekeyto

safeextendedstorageoffoodsisveryrapidchilling

throughthebacterialgrowth“dangerzone.”The

key to retaining food quality, taste, textures and

aromaiscontrolledrefrigeratedstorage.

REVOLUTIONARY COOK-CHILL SOLUTION

ANNUAL SAVINGS CALCULATION CHART UsetoEstimateHowMuchCapKold®CanSaveYou

Multiply your expenses by the savings factors listed below. EXAMPLE:

A) Yearly hot food production labor cost (30-50% savings)* $ x .50 = $ ($500,000 x .50) = $250,000

B) Yearly raw prepared food cost (10% savings)** $ x .10 = $ ($600,000 x .10) = $60,000

C) Yearly labor savings for cleaning pots & pans (8% savings)* $ x .08 = $ ($100,000 x .08) = $8,000

D) Yearly energy cost KW/H (2% savings)* $ x .02 = $ ($30,000 x .02) = $600

GRAND TOTAL (add lines A-D) $ (total savings) = $318,600

*Estimated savings.**10% Savings of raw prepared food cost includes: reduces food waste of 2-3%, recipe standardization savings of 1-2%, purchasing— economy savings of 2%, reduction in pilferage of 1%, and a 3-5% cost savings on increased muscle meat yields of 25-35%.

CALCULATE YOUR YEARLY SAVINGS

CAPKOLD® MENU APPLICATIONSACapKoldSystemcanprepareawidevarietyofpopularmenuentrees,sidedishesanddessertitems,plusmanykeyproductcomponentsorsauces.Hereisjustasample…

Broth&Cream-BasedSoups/Chowders

HeartyStews,Home-StyleCasseroles&More

Sauces,Gravies&Fillings

EthnicSpecialties&OtherItems

PreparedMeats&PreparedFoods

WholeMeatItems

CONTROL, SAFETY, & QUALITYCased Product Time/Temperature ChartRefrigerated Food Bank

Sanitation&FoodSafety• KettleandCookTankcontrolsinclude

time/temperaturechartrecordersforHACCPdocumentation.

• IdealforHACCPfoodsafetyprograms.• Componentsaredesignedtothelatest

sanitarystandards.• Productsarepackagedhot(sanitary).• Durable,multi-ply,flexibleplasticcasings

allowproducttobesafelychilled,storedandrethermalized.

Planning&Control• ACapKoldsystemallowsadvanced

schedulingofproduction,laborandrawmaterialpurchase.

• Employeescanbescheduledonaneight-hour,five-dayoraten-hour,four-dayworkschedule.Holidaysandvacationscanbeeasilyscheduledaroundnormalproduction.

• Outputcantypicallybedoubledortripledwithlittleornoadditionalequipmentinvestment.CapKoldofferscapacityforgrowth.

• Arefrigeratedfoodbankprovidesanemergencyback-upincaseofnaturaldisasteroraworkstoppage.

FoodQuality• CapKoldfoodhasthetaste,texture,color

andaromaoffreshlyprepareditems.• Centralizedpurchasing,ingredient

preparationandproductionprovidesconsistentfoodqualityandmanagedrecipecosts.Ingredientscanbepurchasedinvolume.

• Largequantityautomatedcookingensuresbatch-to-batchconsistency.

• Refrigerated–NOTFROZEN–storagemaintainscellularstructure…keytopreservingtextureandconsistency.

•CookTankitemsslowcookintheirownnaturaljuices-tenderizingtoughercutsofmeat,increasingyieldandenhancingflavor.

COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE

KETTLE COOKING – PUMPABLES Pumpable foods are cooked in CapKold steam-jacketedkettles, with an inclined agitator/mixer and a bottom-mountedproductdischargevalve.Thepatentedinclinedagitatorlifts,foldsandmixeskettleingredients,eliminatingproductburning/scorchingand maintaining batch consistency. The discharge valve allowsefficient transfer of kettle product to a pump-fill station withoutdamagingdelicatefoods. The Kettle Control Panel sequences the cookingcycle, controlling the agitator, temperature and meteredwater. Achartrecorderprovidesatime/temperaturerecordforHACCPandqualityassurance.

PROVEN AGITATOR DESIGNS Groenhasmanufacturedsteamjacketedkettlesforover90years.Wewerethefirsttointroducesteam-jacketedkettlestocommercialandinstitutionalfoodserviceafterWorldWarII.CapKoldoffersawiderangeoflargekettles,agitators,jacketconfigurationsandcontrolpackages.WearetheleaderinKettletechnology.

• CapKoldINA-Seriesinclinedagitatorsareavailableinfixed-agitator,tilt-outagitator(TO),retractablepinnedtilt-outagitator(RTO)andfixedagitator/tilt(TW)withvariations.

• Thenewretractablepinnedtilt-outagitatorisanchoredatthebottomforheavy,viscousproducts.Theagitatorretractsoffananchorthentiltsoutofthekettleeliminatingthecleaningandmaintenanceissuesassociatedwithhorizontalagitators.

• CapKoldN-SeriesPastaKettlesfeaturerim-mounteddrains.

• CapkoldDH/INA/2-100Kettleisaself-contained gas-heatedmodel.

• Alldirect-steamkettlesavailablein50-300gallonworkingcapacities.Largersizesareavailableonrequest.

TRANSFER & PACKAGING Atthecompletionofacookingcycle,thePump-fillStationdrawsproductfromthekettle,measuresapre-setvolume,andfillsaflexibleplasticcasing.Theoperatorusesastation-mountedclippertoseal,attachalabel,andtrimthecasinginonefluidmotion.Oneemployeecantypicallyemptyandpackagetheentirecontentsofa200-gallon(750-liter)kettlein15-20minutes.APump-fillStationcanbesharedbytwoormorekettles.

BETTER FOOD TRANSFER & PACKAGING SOLUTIONS CapKold was first to introduce transfer pumps and air-operated,productvalvestoCook-Chill.

• ThePump-fillStationhandlesabroadrangeofproducttypes,viscositiesandparticulatesizes.

• ThePump-fillStationfeaturesdigitalinputanddisplay,makingadjustmentofpumpspeedandfillvolumequick,preciseandveryeasy.

• Airoperatedcasingclippersandairdrivenvacuumpumpavailableformusclemeatsandcutvegetables.

KETTLE COOKING ➙ HOT FILLING CASING ➙

Proven kettle agitator design

Transferring kettle foods to flexible plastic casings

Station-mounted clipper for sealing, attaching label and trimming casing

Heated, plated and ready to eat

COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE

RAPID TUMBLE CHILLING Thebatchtumblechillerisusedexclusivelyforcoolinglargevolumesofbaggedkettleproduct.Filledcasingsareloadeddirectlyintothechiller,wheretheygentlytumbleincirculatingcoldwater.Thetumblingactionquicklyremovesheatfromthefoodcasingsandchillstheproductinthefastestpossibletime.Anautomaticcontrolsystemmonitorsthechillingtimeandwaterbathtemperature.

WATER-BASED HEAT TRANSFER EXPERIENCE CapKoldwasthefirsttodevelopthebatchtumblechillerandwaterjetconceptsofrapidlycoolingfoodinplasticcasingsorpouches.

• TumbleChillersfeatureallstainlesssteeldesignandprovideupto300-gallonbatchchillingcapability.

• Integratedheatexchangersreduceheightandsimplifycleaning.

• Energysavingicebuilders,directexpansionchillersandfalling-filmchillersprovidecoldwaterusedforproductcooling.

• RecyclingTanksforsavingandreusingproductchilledwater.

• CasingconveyorsspeedandsimplifyTumbleChillerloading.

TUMBLE CHILL CASING ➙

Unloading chilled casings from tumble chiller to food bank storage

Loading filled casings directly into the tumble chiller

WATERJET® COMBINATION TUMBLE COOK CHILL TANK ➙

WATERJET® 100 COOK CHILL TANKThe rapid product cook chill tank is designed to rapidly chill

100-gallons of filled casings in a circulating water bath. The cookchilltankwillslowcookusingsteamslack,prepackagedrawmeats,vegetables and starches; or rapidly reheat prepared foods in itscirculating hot water bath. An internal lift mechanism raises andlowersproductfromthewatereliminatingtheneedforahoist/liftingmechanism.Chillsmostproductsfromtemperaturesofapproximately180°F-40°Fin60minutesorless.Apowerfulwatercirculationpump,fullyautomaticoperatorcontrolpackage,andasheathedandair-gapinsulatedtankwithsplashcoversandliftassistcylindersareincluded.UnitisNSFListed,ULListedandASMEB31.1.

• Featuresinsulating,non-corrodingdoublewallconstructiononexposedtanksidesandfullyenclosedandventedpump/utilityhousing.

• Monitortemperatureswithaprobeforrecordinginternaltemperatureofsolidmuscleproductsanda24hourtime/temperaturerecorderforrecordingwaterandproducttimeandtemperature.

• Waterleveloverflowprotectionandadivertervalvecontrolswaterdischargeflowandturbulence.

• Chilledwaterproductionusesdirectrefrigerationeliminatingtheneedforasecondtankandsavingspace.

• Waterheatingsystemisdirectsteamheatedandrequiresasteamsourceof20-50PSI.

CONTROL PACKAGE• Onetouchcontrolsforchillandheat.

• Step-by-stepprogrammingofcook-to-temperatureandprobe.

• Digitaldisplayofchillingtimeandwatertemperature.

COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE

Fortoday’sperformancekitchens with CapKold cook-

chillproductionsystems,Avtecoffers ventilation and utilitydistribution systems (UDS)tosatisfyyourcustomizationrequirements. Avtec’s high

quality, reliable ventilation hoodshandle theCapKold cookingandheatingparts of your cook-chilloperation. Avtec UDS providessingle point connections for eachutility, ease of installation andmaintenance, and permits futureline-up changes in your cook-chill kitchen. Look to Avtec tocomplement your CapKold cook-chillkitchenoperation.

Avtec® Chinook Hood

REFRIGERATED STORAGE (FOOD BANK) Prepared foods are stored in walk-in refrigerators(commonlyreferredtoasaFoodBank).Temperatureismaintainedjust above the freezing point, to preserve the freshness, texture,colorandqualityofthefood.Menuitemsarepulledfrominventoryasneeded,usedonsite,orshippedtoremoteservingpoints.

HEATING & SERVING CapKold items can be quickly heated to safe servingtemperatures right in the casing, placed in steam table pans, orindividuallyportioned.Groenoffersalineofsteamequipmentthatisperfectforrethermalizingfood. CapKoldfoodsare ideal forpre-platingaspartofa traymakeup and delivery system. They can be used in combinationwith freshly prepared foods and foods which have been blast-chilled.Randelloffersalineofblastchillersaswellasstandardandcustomizedhotandcoldfoodtablesforservingapplications.

WATER BATH SLOW COOKING Whole-meatproducts,suchasroastsandturkeybreasts,andmanypreparedfoodssuchasrice,vegetablesandmeatloaf,can be slow-cooked in a WaterJet or a Cook Tank. Both usecirculatinghotwatertocookproducts,vacuumpackagedinplasticcasings.Attheendofthecookingcycle,theunitsautomaticallydrainandthencirculatecoldwaterforrapidchilling,withouttheproducteverleavingthetank. Water bath slow cooking can be done overnight,unattended. An integral control system monitors both cookingand chillingandprovidesa time/temperatureproduction recordforHACCPandqualityassurance.

PROVEN HOT WATER BATH CapKold pioneered hot water bath, low temperaturecooking of meats and prepared foods in vacuum-sealed plasticcasings.CapKoldCookTanksarecapableofpreparinghundredsofpoundsofperfectrareroastbeefandmore.

• CapKoldCookTanksareavailablewith500-,1000-and 2000-poundnominal.

• DualpurposeTumbleChiller/CookTanksandWaterJets aredesignedforsmalleroperatorsandkitchens.

• Apowerfulwatercirculationpumpprovidesuniform cookingandcooling.

• Abaffledbottomsteamjacketprovidesfastand efficientheatingwithdirectsteam.

• Integratedcontrolsystemsallowovernight, unattendedcooking,coolinganddocumentation.

COOK TANK COOKING ➙ REFRIGERATED STORAGE, HEATING & SERVING

Loading and unloading food product with a push of a button

VENTILATION & UDS

Groen steamers are an excellent way to reheat food in casings or steam pans

Randell RanServehot food tables have integral heaters and are NSF listed

COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE

CapKold’s testkitchen in Jackson,Mississippi isavailable toall cust-omers throughout the various stagesof project development inorder toofferassistancewith:

• Cook-chillorientation• Applicationtesting• Menudevelopmentandmodification• Productdevelopment• Trainingofoperationsand maintenancepersonnel

CapKoldmakesavailabletoallcustomersanon-siteassistanceprogramtosupportthecook-chillproductionsystempurchase. Theprogramincludes:

• SiteInspection:Priortoshipmentofthesystem,CapKoldpersonnelwillconductasitevisitinordertoconfirmlayoutplansandgeneralsitereadinesswiththearchitect,generalcontractor,consultantandotherrequiredindividuals.

CAPKOLD® TEST KITCHEN & ON-SITE ASSISTANCE PROGRAM

Kettle control panel training

• InstallationAdvisoryService:SitevisitbyCapKoldpersonnelasasupervisoryservicetoadvisetheinstallationteamonkeyelementsoftheinstallationoncethesystemisinplace

• EngineeringStartUp:CapKoldpersonnelwillbeonsiteaspartoftheengineeringstart-upinordertocheckandcalibratethesystemandtotrainmaintenancepersonnelandlocalservicetechnicians

• InitialOperationalTraining:CapKold’schef/trainerwillconductinitialoperationalandculinarytrainingtoinclude,butnotlimitedto:-Equipmentorientation-Equipmentcareandsanitation-Equipmentoperation-Recipeadjustmentguidance-Productionschedulepreparationassistance-HACCPandshelflifeguidance-Contactourchefonlinebygoingtohttp://www.unifiedbrands.net/meetthechef.html

888.994.7636unifiedbrands.net

Information contained in this brochure is known to be current and accurate at the time of printing. Unified Brands recommends referencing our website for updated and additional information.

Unified Brands is one of many individual operating companies of Dover Corporation, a multi-billion dollar, global manufacturer of industrial products. The product lines of Unified Brands–Groen, Randell, Avtec and CapKold–have leading industry positions in cooking equipment, cook-chill production systems, custom fabrication, foodservice refrigeration, ventilation and conveyor systems. Headquartered in Jackson, MS, Unified Brands operates manufacturing facilities in Weidman, MI and Jackson, MS.

© 2012 Unified Brands. All Rights Reserved. Unified Brands is a wholly-owned subsidiary of Dover Corporation. Printed in the USA 02/2012

Other quality products from Groen:Steam Jacketed KettlesTilting Braising PansVortex100® Connectionless SteamersSmartSteam100® Boilerless SteamersComboEase™ Combination Oven-Steamers