CapKold Cook-Chill Production Systems User manual

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COOK-CHILL PRODUCTION SYSTEMS

Cook-Chill is a revolutionary way to create meals that look and taste like they were freshly
and individually prepared … yet may have been produced for hundreds to thousands at a time.
CapKold is one of the market leaders in Cook-Chill technology. With dedication to research
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
packaging films to the Cook-Chill concept.
Today,
CapKold provides equipment systems that offer
cost-savings while delivering the fresh taste and
quality of just-cooked food.
CapKold kitchen (from left to right, shown above) -
kettle control panel, (2) kettles, tumble chiller
and pump-fill station
• Cooking, packaging and chilling
equipment allows preparation of
multiple portions in a single batch;
• Sophisticated systems control
equipment and monitor product
through the entire process;
• Combination of plastic casings and
water bath chillers
accelerate chilling and
deliver safe, extended,
refrigerated shelf lives up
to 45 days.
Refrigerated food bank for storage up to 45 days
MATCHING FOOD
PRODUCTION TO DEMAND
The Cook-Chill concept was developed
as a solution to the age-old problem of matching
food production to demand. It separates food
production from food serving by creating a “food
bank” or inventory of prepared product. The key to
safe extended storage of foods is very rapid chilling
through the bacterial growth “danger zone.” The
key to retaining food quality, taste, textures and
aroma is controlled refrigerated storage.
REVOLUTIONARY COOK-CHILL SOLUTION

ANNUAL SAVINGS CALCULATION CHART Use to Estimate How Much CapKold Can Save You
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 APPLICATIONS
A CapKold System can prepare a wide variety of popular menu entrees, side dishes and dessert items, plus
many key product components or sauces. Here is just a sample …
Broth & Cream-Based Soups/Chowders
Hearty Stews, Home-Style Casseroles & More
Sauces, Gravies & Fillings
Ethnic Specialties & Other Items
Prepared Meats & Prepared Foods
Whole Meat Items

CONTROL, SAFETY, & QUALITY
Cased Product
Time/Temperature ChartRefrigerated Food Bank
Sanitation & Food Safety
• Kettle and Cook Tank controls include
time/temperature chart recorders for
HACCP documentation.
• Ideal for HACCP food safety programs.
• Components are designed to the latest
sanitary standards.
• Products are packaged hot (sanitary).
• Durable, multi-ply, flexible plastic casings
allow product to be safely chilled, stored
and rethermalized.
Planning & Control
• A CapKold system allows advanced
scheduling of production, labor and
raw material purchase.
• Employees can be scheduled on an
eight-hour, five-day or a ten-hour,
four-day work schedule. Holidays and
vacations can be easily scheduled
around normal production.
• Output can typically be doubled or
tripled with little or no additional
equipment investment. CapKold offers
capacity for growth.
• A refrigerated food bank provides an
emergency back-up in case of natural
disaster or a work stoppage.
Food Quality
• CapKold food has the taste, texture, color
and aroma of freshly prepared items.
• Centralized purchasing, ingredient
preparation and production provides
consistent food quality and managed
recipe costs. Ingredients can be
purchased in volume.
• Large quantity automated cooking
ensures batch-to-batch consistency.
• Refrigerated – NOT FROZEN – storage
maintains cellular structure… key to
preserving texture and consistency.
• Cook Tank items slow cook in their
own natural juices - tenderizing
tougher cuts of meat, increasing yield
and enhancing flavor.
COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE

KETTLE COOKING – PUMPABLES
Pumpable foods are cooked in CapKold steam-jacketed
kettles, with an inclined agitator/mixer and a bottom-mounted
product discharge valve. The patented inclined agitator lifts, folds
and mixes kettle ingredients, eliminating product burning/scorching
and maintaining batch consistency. The discharge valve allows
efficient transfer of kettle product to a pump-fill station without
damaging delicate foods.
The Kettle Control Panel sequences the cooking
cycle, controlling the agitator, temperature and metered
water. A chart recorder provides a time/temperature record
for HACCP and quality assurance.
PROVEN AGITATOR DESIGNS
Groen has manufactured steam jacketed kettles for
over 90 years. We were the first to introduce steam-jacketed
kettles to commercial and institutional foodservice after World
War II. CapKold offers a wide range of large kettles, agitators,
jacket configurations and control packages. We are the leader
in Kettle technology.
• CapKold INA-Series inclined agitators are available in fixed-
agitator, tilt-out agitator (TO), retractable pinned tilt-out
agitator (RTO) and fixed agitator/tilt (TW) with variations.
• The new retractable pinned tilt-out agitator is anchored at the
bottom for heavy , viscous products. The agitator retracts off
an anchor then tilts out of the kettle eliminating the cleaning
and maintenance issues associated with horizontal agitators.
• CapKold N-Series Pasta Kettles feature rim-mounted drains.
• Capkold DH/INA/2-100 Kettle is a self-contained
gas-heated model.
• All direct-steam kettles available in 50-300 gallon working
capacities. Larger sizes are available on request.
TRANSFER & PACKAGING
At the completion of a cooking cycle, the Pump-fill Station
draws product from the kettle, measures a pre-set volume, and fills a
flexible plastic casing. The operator uses a station-mounted clipper
to seal, attach a label, and trim the casing in one fluid motion. One
employee can typically empty and package the entire contents of a
200-gallon (750-liter) kettle in 15-20 minutes. A Pump-fill Station
can be shared by two or more kettles.
BETTER FOOD TRANSFER
& PACKAGING SOLUTIONS
CapKold was first to introduce transfer pumps and air-
operated, product valves to Cook-Chill.
• The Pump-fill Station handles a broad range of product types,
viscosities and particulate sizes.
• The Pump-fill Station features digital input and display,
making adjustment of pump speed and fill volume quick,
precise and very easy.
• Air operated casing clippers and air driven vacuum pump
available for muscle meats and cut vegetables.
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