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COOK-CHILL PRODUCTION SYSTEMS
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REVOLUTIONARY COOK-CHILL SOLUTION
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.
•
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
to 45 days.
shelf lives up
Refrigerated food bank for storage up to 45 days
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.
CapKold provides equipment systems that offer
cost-savings while delivering the fresh taste and
quality of just-cooked food.
Today,
CapKold kitchen (from left to right, shown above) kettle control panel, (2) kettles, tumble chiller
and pump-fill station
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.
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CALCULATE YOUR YEARLY SAVINGS
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%.
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
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COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE
CONTROL, SAFETY, & QUALITY
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.
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.
Time/Temperature ChartRefrigerated Food Bank
Cased Product
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.
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KETTLE COOKING
Proven kettle agitator design
➙
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.
HOT FILLING CASING
➙
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.
Transferring kettle foods to flexible plastic casings
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 fixedagitator, 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.
Station-mounted clipper for sealing, attaching
label and trimming casing
Heated, plated and ready to eat
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.
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COOK-CHILL PRODUCTION SYSTEMS AT A GLANCE
TUMBLE CHILL CASING
Loading filled casings directly into the tumble chiller
➙
RAPID TUMBLE CHILLING
The batch tumble chiller is used exclusively for cooling large
volumes of bagged kettle product. Filled casings are loaded directly
into the chiller, where they gently tumble in circulating cold water.
The tumbling action quickly removes heat from the food casings and
chills the product in the fastest possible time. An automatic control
system monitors the chilling time and water bath temperature.
WATER-BASED HEAT TRANSFER EXPERIENCE
CapKold was the first to develop the batch tumble chiller and
water jet concepts of rapidly cooling food in plastic casings or pouches.
• Tumble Chillers feature all stainless steel design and provide
up to 300-gallon batch chilling capability.
•
Integrated heat exchangers reduce height and simplify cleaning.
• Energy saving ice builders, direct expansion chillers and fallingfilm chillers provide cold water used for product cooling.
• Recycling Tanks for saving and reusing product chilled water.
WATERJET™ (COMBINATION TUMBLE
CHILLER & COOK TANK)
WATERJET 100
The WaterJet is a Rapid Product Chiller/Cook Tank designed to
rapidly chill 100-gallons of filled casings in a circulating water bath.
The WaterJet will slow cook using steam slack, prepackaged raw
meats, vegetables and starches; or rapidly reheat prepared foods in
its circulating hot water bath. An internal lift mechanism raises and
lowers product from the water eliminating the need for a hoist/lifting
mechanism. Chills most products from temperatures of approximately
180°F-40°F in 60 minutes or less. A powerful water circulation pump,
fully automatic operator control package, and a sheathed and air-gap
insulated tank with splash covers and lift assist cylinders are included.
Unit is NSF Listed, UL Listed and ASMEB31.1.
• Features insulating, non-corroding double wall construction
on exposed tank sides and fully enclosed and vented pump/
utility housing.
• Monitor temperatures with a probe for recording internal
temperature of solid muscle products and a 24 hour time/
temperature recorder for recording water and product time
and temperature.
➙
• Casing conveyors speed and simplify Tumble Chiller loading.
Unloading chilled casings from tumble chiller to food bank storage
• Water level overflow protection and a diverter valve controls
water discharge flow and turbulence.
• Chilled water production uses direct refrigeration eliminating
the need for a second tank and saving space.
• Water heating system is direct steam heated and requires a
steam source of 20-50 PSI.
CONTROL PACKAGE
• One touch controls for chill and heat.
• Step-by-step programming of cook-to-temperature and probe.
• Digital display of chilling time and water temperature.
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COOK TANK COOKING
➙
WATER BATH SLOW COOKING
Whole-meat products, such as roasts and turkey breasts,
and many prepared foods such as rice, vegetables and meatloaf,
can be slow-cooked in a WaterJet or a Cook Tank. Both use
circulating hot water to cook products, vacuum packaged in plastic
casings. At the end of the cooking cycle, the units automatically
drain and then circulate cold water for rapid chilling, without the
product ever leaving the tank.
Water bath slow cooking can be done overnight,
unattended. An integral control system monitors both cooking
and chilling and provides a time/temperature production record
for HACCP and quality assurance.
REFRIGERATED STORAGE,
HEATING & SERVING
REFRIGERATED STORAGE (FOOD BANK)
Prepared foods are stored in walk-in refrigerators
(commonly referred to as a Food Bank). Temperature is maintained
just above the freezing point, to preserve the freshness, texture,
color and quality of the food. Menu items are pulled from inventory
as needed, used on site, or shipped to remote serving points.
HEATING & SERVING
CapKold items can be quickly heated to safe serving
temperatures right in the casing, placed in steam table pans, or
individually portioned. Groen offers a line of steam equipment that
is perfect for rethermalizing food.
CapKold foods are ideal for pre-plating as part of a tray
makeup and delivery system. They can be used in combination
with freshly prepared foods and foods which have been blastchilled. Randell offers a line of blast chillers as well as standard and
customized hot and cold food tables for serving applications.
Groen steamers
are an excellent
way to reheat
food in casings
or steam pans
Randell RanServe
hot food tables
have integral
heaters and are
NSF listed
Loading and unloading food product with a push of a button
PROVEN HOT WATER BATH
CapKold pioneered hot water bath, low temperature
cooking of meats and prepared foods in vacuum-sealed plastic
casings. CapKold Cook Tanks are capable of preparing hundreds
of pounds of perfect rare roast beef and more.
• CapKold Cook Tanks are available with 500-, 1000- and
2000-pound nominal.
• Dual purpose Tumble Chiller/Cook Tanks and WaterJets
are designed for smaller operators and kitchens.
• A powerful water circulation pump provides uniform
cooking and cooling.
• A baffled bottom steam jacket provides fast and
efficient heating with direct steam.
• Integrated control systems allow overnight,
unattended cooking, cooling and documentation.
VENTILATION
& UDS
For today’s performance
kitchens with CapKold cook-
chill production systems, Avtec
Avtec
®
Chinook Hood
quality, reliable ventilation hoods
handle the CapKold cooking and heating parts of your cook-chill
operation. Avtec UDS provides
single point connections for each
utility, ease of installation and
maintenance, and permits future
line-up changes in your cookchill kitchen. Look to Avtec to
complement your CapKold cookchill kitchen operation.
offers ventilation and utility
distribution systems (UDS)
to satisfy your customization
requirements. Avtec’s high
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FOODSERVICE EQUIPMENT SOLUTIONS
CAPKOLD TEST KITCHEN & ON-SITE ASSISTANCE PROGRAM
CapKold’s test kitchen in Jackson, Mississippi is available to all customers throughout the various stages of project development in order to
offer assistance with:
• Cook-Chill orientation
• Application testing
• Menu development and modification
• Product development
• Training of operations and
maintenance personnel
CapKold makes available to all customers
an on-site assistance program to support the
cook-chill production system purchase. The
program includes:
• Site Inspection: Prior to shipment of the system, CapKold personnel
will conduct a site visit in order to confirm layout plans and general
site readiness with the architect, general contractor, consultant and
other required individuals.
Kettle control panel training
• Installation Advisory Service: Site visit by CapKold personnel
as a supervisory service to advise the installation team on key
elements of the installation once the system is in place
• Engineering Start Up: CapKold personnel will be on site as
part of the engineering start-up in order to check
and calibrate the system and to train maintenance
personnel and local service technicians
• Initial Operational Training: CapKold’s
chef/trainer will conduct initial operational
and culinary training to include, but not limited to:
- Equipment orientation
- Equipment care and sanitation
- Equipment operation
- Recipe adjustment guidance
- Production schedule preparation assistance
- HACCP and shelf life guidance
- Contact our chef online by going to
http://www.unifiedbrands.net/meetthechef.html
888-994-7636 • unifiedbrands.net
Information contained in this document is known to be current and accurate at the time of printing.
Unied Brands recommends referencing our product line websites for the most updated product information and specications.
CK 06/08 (3m)
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