Answers to the most frequently asked questions about cook/chill processing and the Bally Northwind 500 and 1000

Definitions:

Cook Chill Food Production:
A food production system that functions on the principle of cooking food to a "just done" state, followed by rapid cooling and storage under controlled temperature conditions. In simple terms, a "cook-to-inventory" system.

Air-Blast Chilling:
The utilization of high-velocity, convected air cycling in temperature ranges below 38�F/3.3�C to rapidly cool packaged foods.

Water-Bath Chilling:
Encasement of cooked foods in Cryovac bags with subsequent immersion in cold circulating water to rapidly cool foods.

Food Banks:
Walk-in inventory holding rooms solely designed for storage of chill-processed food Inventories.

Danger Zone for Food Handling:
The temperature zone through which a food must be heated or cooled quickly to control food spoilage and food-borne poisoning. This zone currently is defined by foodservice sanitarians as 140�F to 45�F (60�C to 7.2�C). The cumulative time period that a food can be in the range is four hours. RULE. 140�F - 45�F (60�C - 7.2�C) for 4 HRS.

  Frequent questions:

• How much food can I process and how long will it take?
• Can I process different products at the same time?
• What containers can I use?
• What foods can I process?
• I'm considering a kettle system because of the large quantities of pumpable food that must be produced. Do I really need a blast chiller too?
• What is the relationship between chilling time and storage life?
• Can I use my standard walk-in refrigerator to chill processed foods?
• Do food bank storage temperatures affect shelf life?
• Are blast-chilled products susceptible to the transfer of food-borne illness?
• I'm an institutional feeder; our patrons depend on our food service for three meals a day, seven days a week. We must serve nutritionally balanced meals. Will chill processing affect the nutritional quality of the foods served?
• Will blast-chilled foods taste like leftovers?
• What are the advantages of using the chilled food bank concept?
• How do I determine food production load times since my menu changes several times a year?
• Where else can I use Bally products in my chilled foods system?

Blast Chill Food Processing Flow Chart with Applications for Bally Refrigeration Systems

Blast Chilling Questions & Answers

• How much food can I process and how long will it take?
  The quantity of food that can be processed in the Bally Northwind 1000 is determined by the food container holding capacity of the cart. Each Northwind cart has nine slide positions; fully loaded, the Northwind holds two carts.
  Each cart has universal slides, each holding one 18" x 26" x 1" (457.2mm x 660.4mm x 25.4mm) sheet pan* or two 12" x 20" x 2�" (304.8mm x 508mm x 63.5mm) steam table pans. Fully loaded cart capacity will vary with the count, weight and density of product placed on pans.
  The rule-of-thumb to use when determining processing capacity is: One 12" x 20" x 2�" (304.8mm x 508mm x 63.5mm) steam table pan holds 12 lbs. (5.44 kgs) or 6 qts. (5.68 liters) of product. Two 12" x 20" x 2�" (304.8mm x 508mm x 63.5mm) steam table pans per cart slide = 24 lbs. or 12 qts. of product.
  Eighteen 12"x 20" x 2�" (304.8mm x 508mm x 63.5mm) steam table pans per loaded cart = 216 lbs. or 108 qts. of product.
  Thirty-six 12" x 20" x 2�" (304.8mm x 508mm x 63.5mm) steam table pans per fully loaded Northwind 1000 = 432 lbs. (196 kgs.) or 216 qts. (204 liters) of product.
  The processing time for food that can be chilled in the Bally Northwind 1000 depends on the food product entry temperature, density, fat and moisture content, packaging, specific heat, etc. To obtain faster cool-down, product should be no more than 2" (50.8mm) deep. Very large cuts of meat and pans such as 4" (101.6mm) and 6" (152.4mm) steam table pans, saucepans and stock pots should not be used.
  Generally, 26 steam table pans cool through the danger zone in 1 to 1� hours. This processing speed allows for five to seven batches of product per eight-hour production period with the capacity to process one last batch or larger, more time-consuming items, such as meat roasts, overnight.
  Remember - In a central production kitchen, the capacity of the Northwind 1000 must match the output of the cooking equipment and packaging operation in order to fully utilize the chiller. Cooked food should never be held outside the unit awaiting the next loading.

*Sheet pans are used to hold meat patties, steaks, chops, bacon, sausage, etc. and capacity is determined by count.

*Includes 1 overnight loading

Back to questions.

• Can I process different products at the same time?
  Different food products give up their heat at different rates, irrespective of the capacity of the refrigeration system. Blast chilling in the Northwind therefore should be integrated with the cooking and preparation of similar products; mixed cart loads should be avoided. Back to questions.
• What containers can I use?
  Containers should be moisture- and vapor-proof with the ability to be labeled and transferred without splitting or spillage occurring. Coated aluminum steam table disposable pans by Reynolds, stainless steel steam fable pans with snap lock lids by Vollrath, or Cryovac bags by W.R. Grace and Co. are recommended. Back to questions.
• What foods can I process?
  Any food can be processed in the blast chiller as long as air temperatures do not produce product freezing. However, in large volume operations, liquid and semi- viscous items such as soups, sauces, Jell-O, gravies, fillings and puddings lend themselves to easier handling with kettle-pump fill and water-bath chill processing.
  Items ideal for blast chill processing are breakfast items including all types of egg preparations, waffles, pancakes, crepes, quiche, sausages, bacon, and cooked cereals; entree items such as individual and bulk-portioned casseroles; layered ethnic dishes such lasagna and eggplant Parmesan; other Italian dishes; vegetables; starches such as rice, potato and macaroni items; hamburger patties, broiled steaks and chops; fried and broiled chicken and fish; meat loaves; meat stews; briskets; turkey parts; Cornish hens; sliced meat roasts with gravy; and pre-plated meal combinations.
  The blast chiller can also be used to chill salad and sandwich filling, including potato, macaroni, cole slaw, tuna, salmon, crab, chicken, turkey, ham and egg salad fillings. Rapid chill-down of these products is particularly important because of the hazardous combination of egg and protein base dressings being mixed with raw chopped vegetable ingredients (e.g. celery) that are frequently sources of bacterial contamination. Back to questions.
• I'm considering a kettle system because of the large quantities of pumpable food that must be produced. Do I really need a blast chiller too?
  Yes. Statistically, 40 percent of your menu can be cooked in kettles and then pump-filled into Cryovac bags for water-bath processing. Roasts and poultry can also be processed using the Cryovac and water bath methods. This still leaves a void in production of delicate items such as eggs, vegetables, individual and bulk casseroles in addition to fried and broiled meat, poultry and fish preparations.
  Remember - every cook/chill kettle system should be specified with a blast chiller to accommodate future changes in menu variety and production capacity. Historically, this has been the failure of cook/chill systems. Their designs were specialized and did not allow the food-service operator the production flexibility he needed to adjust to changing demands. Back to questions.
• What is the relationship between chilling time and storage life?
  Without doubt the most important aspect of any cook/chill processing system is the critical link between chilling rate and storage life. First, food must be chilled immediately on completion of the cooling process. Food spoilage occurs mainly because of bacteriological activity within the 45�F/7.2�C to 140�F/60�C danger-zone. It is generally accepted that in order to retain color, flavor, texture and nutritional value, cooked food should be chilled through the danger zone in a period of two hours or less. If chill-down takes longer, bacterial growth can reduce quality and safe storage life. Back to questions.

• Can I use my standard walk-in refrigerator to chill processed foods?
  Standard forms of refrigeration cannot be used for chill processing because they are not engineered to cope with the large quantities of heat that must be quickly removed from the hot product. When hot product is placed into a standard walk-in system, insulating layers of heat form around the food product. These insulating layers of heat prevent direct heat transfer from the product into the cooler refrigerated air. Slow product cooling results. Therefore, eight or more hours may be required to thoroughly cool the product below 40�F (4��C).
  In addition, the compressor of a walk-in used this way is never cycled off. Continuous operation is a result of undersized coils that can't properly remove the large quantities of heat in the product zone. Great stress is placed on the mechanical system, reducing its useful life.
  The blast chilling system of the Northwind 1000 is designed to take hot food quickly down in temperature through the use of fans, producing high-velocity convected airflow within the product zone. This strips away the insulating layers of heat, thus increasing the rate of heat transfer out of the food. Large capacity cooling coils efficiently remove that heat from the product zone. Because of the fast product cool- down, foods are safer for consumption and they look and taste fresher since contamination has not had time to develop. Rapid cool-down also eliminates that "leftover taste" that sometimes occurs in refrigerated foods. It also retards the breakdown of heat-liable nutrients such as ascorbic acid (vitamin C). Back to questions.
• Do food bank storage temperatures affect shelf life?
  "General purpose" storage temperatures are not acceptable in an inventory holding area for precooked chilled foods. The temperature of the food bank directly determines the length of storage life.
  If the products have been chill processed in two hours or less, the following food bank storage lives will result:

*In the interest of safety, storage time should not exceed five days.

Back to questions.

• Are blast-chilled products susceptible to the transfer of food-borne illness?
  Several factors contribute to the development of food-borne illness organisms in food. For growth, five factors must be present: a source of nourishment, neutral to slightly acid or alkaline environment, moisture, warmth and time. A food product supplies the first three factors and a careless food handler contributes the last two.
  If you purchase fresh, high-quality products, prepare them under clean, sanitary conditions, properly cook them to temperatures above 160�F/71�C for sufficient periods of time, and maintain good, sanitary handling practices when packaging the hot product, then the rapid cool-down time of the Northwind 1000 should assure the wholesomeness of the food.Back to questions.
• I'm an institutional feeder; our patrons depend on our food service for three meals a day, seven days a week. We must serve nutritionally balanced meals. Will chill processing affect the nutritional quality of the foods served?
  Nutrients such as water-soluble vitamins and minerals (e.g. thiamine) and easily oxidized vitamins (e.g. vitamin C) are a concern in processed foods. Tests have shown that, as compared to their nutritional value in foods held for periods exceeding 45 minutes on a steam table, the value of these delicate nutrients was far higher in food which was chill processed and reheated for immediate service.Back to questions.
• Will blast-chilled foods taste like leftovers?
  Exposure to air and lengthy holding periods in the 140�-45�F (60�-7.2�C) "danger zone" create the color, flavor and texture changes associated with reheated refrigerated foods. Properly covered product that is chilled quickly has no "left over taste." In fact, flavors are enhanced because delicate spices have time to properly cure during cold storage, producing more flavorful mixed meat recipes such as meat loaf and beef stew and enriched flavors in Italian dishes. Back to questions.
• What are the advantages of using the chilled food bank concept?
  The peaks and valleys normally associated with cook-serve operations are eliminated. Production is generally handled in eight hour shifts, five days per week, instead of the normal twelve-hour shift, seven days per week. As a result, production staffing may be reduced.
  • Food production can be centralized, making cook/chill ideal for satellite operations where food is distributed from one source to multi-units or service sites.
  • Kitchen space is usually used more efficiently by employing high volume, bulk production equipment that is utilized more throughout the day.
  • Quality and consistency are improved by more controlled production techniques and by the ability to better utilize more highly skilled labor totally dedicated to performing food production techniques. Back to questions.
• How do I determine food production load times since my menu changes several times a year?
  The Northwind 1000 is supplied with a temperature probe. Insert the probe into the center of a representative portion of product and record the time it takes to reach the desired cool- down temperature during the initial load processing. The digital temperature readout on the exterior control panel will indicate the food's core temperature. Maintain a production record of these times. When a similar product is processed the probe need not be used. Just use the manual time to run the processing cycle. To clean the probe tip, dip it in a sanitizing chemical recommended for use on food contact surfaces and wipe it with fresh water and a clean cloth. Back to questions.
• Where else can I use Bally products in my chilled foods system?
  When we use the term "cook/chill" we are describing an eight-stage food production process. Each stage is interdependent on the others. Refrigeration has an important role to play in six of these eight Stages.
  1. Preparation
  2. Cooking
  3. Chilling
  4. Portioning
  5. Storage
  6. Distribution
  7. Re- thermalization
  8. Service.

  Back to questions.

  The following flow diagram illustrates the applications for Bally's walk-ins:

Blast Chill Food Processing Flow Chart with Applications for Bally Refrigeration Systems

• Receivable Storage
  (0�F/-17.7�Cand 38�F/3.3�C walk-ins-for frozen products, -10�F to 0�F (-23.3�C to -17.7�C); meats, 30�F/-1.1�C; wet fish, 32�F/0�C; produce and dairy products, 38�F/3.3�C)
• Ingredient Room
  (38�F/3.3�C walk-in for portioned and prepped product awaiting transfer to cooks' area)
• Cook Processing and Packaging
• Blast Chill Processing (5�F/-15�C to 38�F/3.3�C blast chill processing walk-in)

  Bulk Pan Food Bank Storage	Pre-plates Portioning (50�F/10�C Refrigerated walk-in room)
  Portioning (50� F/10�C refrig. room)	Food Bank Storage*

• Distribution
  (Carts and carriers are held in 38�F/3.3�C walk-ins until transported)

*Food Bank Storage:
Walk-in temperatures for long-term storage of chilled product vary depending on desired storage life:

38� to 40�F (3.3� to 4��C) Blast Chilled Product - 2 days
36� to 38�F (2.2� to 3.3�C) Blast Chilled Product - 3 days
28� to 33�F (-2.2� to ��C) Blast Chilled Product - 5 days
28� to 33�F (-2.2� to ��C) Cryovac Water Chilled Product - 45 days.

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