Rethermalization is an essential part of COOK-CHILL.  The cook-chill process involves central food production, refrigeration or freezing of food for later use, and rethermalizing when the food is needed for serving. Rational combi ovens rethermalization enable remote feeding areas to reheat large quantities of food for serving, with minimal investment in equipment or space.  Large centralized kitchens, such as certain school districts in PA. utilize this type of process for serving school lunches.

Reheating large quantities of food requires precision engineered heating systems to bring food to serving temperature.  You can’t just blast food with a lot of hot air and expect to get good results.  Rational combi ovens offers an intelligent system for even heating and customized cooking cycles – each with a precise, temperature profile to achieve the best result in food quality, most efficiently, and with ease.  For more information take a look at the new Rational SCC WE video.

Design & Processing Resources is proud to introduce the DPR14 lab kettle.  Designed specifically for labs that were originally doing fly larva, this unit caught on and is now used in several R&D facilities.  With temperatures up to 400 F, heating and cooling capabilities, PLC touch screen display, formulation storage, and stainless steel construction this unit meets the stringent demands of our clients.

As a result of work done on a kettle by a non authorized service tech., a kettle exploded in a restaurant.  It injured workers and destroyed the kitchen.  In addition to the work done by the repair technician, the age of the kettle and lack of routine maintenance also played a role in the explosion.  Below is a video of the kettle and the investigator’s comments and findings.  The kettle was not a Groen and the investigator is an independent investigator.

Design & Processing Resources Inc. is known for it’s fondant, icing, and frosting manufacturing lines it designs and builds.  Below is a video of one of the key pieces of equipment in designing these lines with efficiency, accuracy, and production reliability.

Design & Processing Resources Inc. now offers a mixer stand that is portable and power assisted.  This makes adding a mixer to your Groen kettle a breeze.  This also means that you can share one mixer between kettles because the mixers are not mounted to the kettles.  Below are some details.  For pricing and info give us a call at 866-807-4500

• Power-assist raising and lowering of the mixer’s shaft into the tank.
• All stainless steel construction.
• Availability with a 36-, 48- or 60-inch stroke length.
• Your selection from the ELS electric series (which includes a remote control, a 1/2-HP motor with a worm gear drive, the ability to be electro-polished and ASME-BPE validation) or the ALS compressed air series.
• Compliance with USDA paint-free equipment mandates.  FDA compliant model also available.
• A variety of options, such as counterweights, adjustable leveling guides and locking casters.

OMH Bureau of Nutrition Services

Director
William Schaefer

Cook Chill Production Center Director
Josephine Fulbrook

The employees of the CCPC have developed this program with pride.

Mission of the Cook/Chill Production Center (CCPC):

Our cook chill system of manufacturing enables us to offer fresh, wholesome meals that are fully prepared, and meet the nutritional and budgetary needs of our patients and customers.

What is the CCPC?

The CCPC is a central food processing plant operated by the Bureau of Nutrition Services of the New York State Office of Mental Health (OMH). The CCPC operating since October of 1994, by the New York State Office of Mental Health, Bureau of Nutrition Services, serves OMH facilities, other state agencies, government and Not-For-Profit agencies. Refrigerated trucks deliver food from Buffalo to Long Island. Cook/Chill is a system which prepares large quantities of food with an extended shelf life. This extended life comes from the control of time and temperature.

• Food is cooked at pasteurization temperatures to kill harmful bacteria
• Food is chilled quickly (within one hour) to prevent bacteria growth
• Food is stored and shipped at 28-32° F

What is the Shelf-Life of these foods?

• Tumble chilled & cook tank products have a shelf life of 4 weeks or more.
• Specialty products have shelf lives of 1-2 weeks.
• Salad such as tuna salad, egg salad, and chicken salad have shelf lives of 15 days.

Facts

• The CCPC makes over 150 different products.
• The CCPC prepares traditional home style comfort foods.
• The cook chill production center currently services 75 meal sites.
• Daily pounds produced = 25,000 lbs.
• Products have an extended refrigerated shelf life of 4-6 weeks.
• Cook chill products reduce food and labor costs.

Cook Chill Products

Kettle Products

Food is prepared in automatic steam-jacketed kettles, then pumped into plastic “casings” and tumble-chilled from 180°F to 40°F in one hour. Examples of these products are:

• Vegetable Soup
• Minestrone Soup
• Chili & Vegetarian Chili
• Arroz con Pollo
• Chicken Cacciatore
• Macaroni & Cheese
• Pudding
• Gravies
• Beef Stew
• Cheese Sauce
• Marinara Sauce
• Fruit Compotes

Cook Tank Products

Whole meats are sealed in plastic bags and cooked slowly in a water bath; at the correct level of doneness, chilled water is pumped in and cooked meat is held in a chilled state. Examples of these products are:

• Roast Beef
• Meatloaf
• Turkey Breast
• Pork Oriental
• Fajitas

Why Cook / Chill ?

• Food tastes fresher and less energy is used in preparation, storage, and rethermalization.
• Labor normally devoted to food production can be reduced by about 50%.
• There is increased menu flexibility.
• Production staff can devote their time to other duties.
• Cook/Chill eliminates “peaks & valleys” in food production workloads.
• Emergencies, such as weather or staff shortages, are more easily handled.

How is Safety & Quality Insured?

• The CCPC operates under USDA Regulations and follows a HACCP Plan to insure safety. (Hazard Analysis Critical Control Points).
• The CCPC test kitchen develops new recipes and enhances existing ones.
• The CCPC lab tests for pH and viscosity. It prepares samples for microbial testing by an outside lab.
• All equipment is automated, including truck temperature monitoring.

How are Cook/Chill Foods Rethermalized?

• Foods can be rethermalized directly in their casings in kettles, braising pans, steamers, or combi-ovens.
• Foods can be removed from casings and combined (sliced meats plus gravy, for example) and rethermalized in an oven or steamer.
• Rethermalized foods can be served hot on a cafeteria line, on a central tray-line, of in a conventional kitchen.
• Foods can be plated chilled and rethermalized individually via an “on-plate rethermalization system”.

Advantages to cook chill systems

1) High Volume: Produce larger volumes in less time with better results.

2) High Production: Produce a greater variety of foods to meet changing menu and customer demands.

3) High Consistency: Duplicate the same excellent results, each time and every time.

4) Increase Efficiency: Reduce the expense of labor, food, and other costs by 20 to 50%.

5) Innovation: Create methods of food production that provide desired results.

Cook Chill Menu Items:

Many menu items can be produced in Cook Chill equipment – soups, sauces, stews, casseroles, salad dressings, cold salads, gelatins, pie fillings, whole meats, and many ethnic specialties.

Mixer Kettles:

Any product that will flow can be cooked in a Mixer Kettle and pumped with a Food Pump into Cook Chill bags or pans.

This produces consistently high quality food by:

Mixing gently yet thoroughly while cooking to achieve the desired textures and flavors.

Pumping product with a piston food pump to retain the shape and quality of the food.

Cooking to the desired doneness and rapidly chilling to stop the cooking process and retain quality.

Producing hot or cold recipes while maintaining food safety standards.

Cook Tanks & TurboJet:

Meats and many other foods such as rice, potatoes and vegetables can be cooked in a Cook Tank or TurboJet. Both use a low temperature water bath to slow cook the vacuum packaged products.

Design & Processing Resources Inc. has noticed and increase in customers in Canada and also Central America.  In order to help support these customers, DPR Inc. has added sites and locations for 2011 to these regions.  Translators are also available for French, Spanish, and Portuguese speaking customers.

Design & Processing Resources Sites:

Canada : www.designprocessinc.ca

Mexico : www.designprocessinc.mx

Design & Processing Resources Inc. is a leader in the industry of food, pharmaceutical, nutriceutical, and cosmetic industry.  We have a strong philosophy about educating our customers and providing the best service possible.  Below is a video on making beer as hosted on the Discovery channels “How it’s made”.  If you have any questions please feel free to contact us at toll free 866-807-4500.

Design & Processing Resources Inc. is a leader in the industry of food, pharmaceutical, nutriceutical, and cosmetic industry.  We have a strong philosophy about educating our customers and providing the best service possible.  Below is a video on making mustard as hosted on the Discovery channels “How it’s made”.  If you have any questions please feel free to contact us at toll free 866-807-4500.