An Introduction to:

Cook Chill AdvancedFood Production Systems

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It's all about offeringmore choices & providing better solutions.

Cook /Chill Systems

Cook ChillOverview

COOK CHILL FOOD PRODUCTION is a process of cooking food to a "just done state", packaging in tough oxygen impervious casing at pasteurization temperature, and then rapid chilling to 40°F in less than one hour. This enables the "Fresh Product", which has not suffered structural degradation via freezingor high temperature canning to be stored in a refrigerated Food Bank for up to 45 days (depending onproduct).

The product can then be:A/ Rethermalized in its' original casings or in pans at the production location.B/ Transported cold to satellite locations to reheat and serve in its' original casings or in pans.

With the addition of ancillary support equipment (including conventional production and refrigeration equipment) afully integrated, synergistic, operational advanced food production system is ensured.

COOK CHILL PRODUCTION ADVANTAGESThe main difference between Cook Chill and Cook Serve operations is that Cook Chill production fills an inventory or"Food Bank" for future use, and Cook Serve is intended for immediate use.

• Having a pre-stocked inventory eliminates the peaks and valleys associated with Cook Serve operations.

• Production time is reduced by approximately 45%. Menu items for a seven day around the clock facility can now be produced in five/eight hour shifts per week.

• Production can be centralized for operations where food is distributed to off-site locations.

• Space allocation for production is usually reduced by employing high volume equipment.

• Quality and consistency of the finished product is improved by the use of controlled production techniques.

CONCLUSIONCook Chill is not a mystical cooking system. Virtually every step in conventional food production is repeatedduring the Cook Chill cooking cycle with exacting standards. The key elements are controlled cooking and rapid chilling of the product thus eliminating degradation to food quality caused by high temperature holding orfreezing.

The result of a Cook Chill system is consistent food quality, with optimal color, texture, moisture content and nutritional value.

Cook Chill Food Preparation offers flexibility for a wide array of menu styles. Basically any stylemenu, excluding short-order grilled foods, can beproduced and served in a Cook Chill System. Due to efficiencies in production and a chilled inventory, a wider variety of daily choices can be made available to clients with both cycle and restaurant style menus.

Food quality can actually beimproved with conversion to aCook Chill System.

With conventional systems, food is subject to high temperaturesfor long periods of time resulting in a loss of moisture, color and texture. Consequently, quality atthe point of service issignificantly compromised andoften inconsistent.

With a Cook Chill System, theopportunity exists to serveconsistently high quality foodproducts by:

1. Standardization of recipes and batch preparation of products.

2. Cooking only to desireddoneness and rapidly chilling to stop the cooking process.

3. Rethermalization of products prior to service, avoiding hot holding forextended periods of time.

Cook Tank Products

Because the meat is cookedslowly, at a low temperature, even the least tender items are made tender. There is an average of 25% less shrinkagedue to no evaporative and drip loss producing a more juicyproduct.

The cooking skill required is in recipe development and determining sauces, etc.. This type of cooking is a controlled, even, slow, water bath method, with no danger of over-cooking. The cook does not have to remember to turn the pan, take the product out of the oven or determine doneness. This means the"guesswork" is taken out of the process, which results in fewer mistakes and less waste.

After the meat is cooked and chilled it is still protected bythe casing and therefore as it is held in the very lowtemperature refrigerator it does not lose or change flavorand it maintains its' high quality.

Cook Tank items are usually thought of as meat items only.

Here are a few more suggestions:

• Spanish Rice • Potatoes for Hash Browns • Buttered Rice • Beets in Orange

Sauce • Candied Sweet Potatoes • Sweet N' Sour Pork • Harvard Beets •

Parsley Buttered Potatoes • Meat Loaf • Meat Balls • Salisbury Steak • Baked

Chicken Breasts • Quartered Chicken for BBQ • Baked Ham, slices or whole •

Corned Beef • Short Ribs • Pork Chops • Pot Roast • Roast Beef • Roast Turkey

• Rice Pilaf • Swiss Steak • BBQ Ribs

Kettle Products

Any liquid product, or productthat will flow when hot can bepumped by the ClevelandMetering Filling Station.

Sauces & Gravies- An Endless Variety.

• Cream Sauce • Cheese Sauce • Au Jus •

Tomato - Lasagna Marinara, Pizza &

Spaghetti Sauces • Enchilada Sauce •

Jardiniere Sauce • Cheese Sauce - used

with Au Gratin Vegetables • Mustard Sauce

- Chinese • Orange Sauce for Roast Duck •

Chili Con Quesa • Nacho Sauce • Barbecue

Sauce • Cream Sauce for Vegetables •

Raisin Sauce • Beef, Chicken, Turkey, Pork,

or Veal Gravy • Giblet Gravy • Cream Gravy

• Country Gravy

Cold Products -

• Fruitbread & Muffin Batters • Salad

Dressings • Salads - Potato, Macaroni, or

Meat

Chinese Dishes - A few to consider.

• Cashew Chicken • Beef or Chicken Chow

Mein • Beef and Broccoli • Ginger Beef

Mexican Dishes - Always the favorites.

• Refried Beans • Taco Meat • Enchilada Sauce • Nacho Cheese Sauce

Soups - Here is where the real efficiency is. Create your own specialized recipe.

• Broth Soups - Beef or Chicken Noodle, Beef or Chicken Rice, Won Ton,

Alphabet Soup, Beef Barley, French Onion, English Barley • Cream Soups -

Tomato, Mushroom, Asparagus, Broccoli, Carrot, Chicken, Potato • Hearty

Chowders & Soups - Corn Vegetable, Minestrone, Navy Bean, Clam Chowder,

Split Pea

Dishes to Fit Everyone's Palate - Or convert your own favorite recipe.

• Pork & Beans • Barbecued Beef • Beef Tips in Mushroom Gravy • Beef Cubes

in Brown Sauce • Beef Goulash • Beef & Macaroni Casserole • Macaroni &

Cheese • Beef Stew • Beef Stroganoff • Pot Pie Filling • Chili Con Carne • Stews

of all kinds • Curry dishes of all kinds • Sloppy Joe • Stewed Tomatoes • Turkey

Ala King • Whipped Potatoes • Tuna Noodle Casserole

MenuFood for Thought

Food quality can actually be improved withconversion to a Cook Chill System.

Planning & Food Preparation

Cooking, Packaging & Chilling

Storage & Rethermalization

1. Central Planning/ SchedulingTo suit the operators volume and menu requirements, Cook Chill products are

prepared to fill an inventory or food bank well in advance of serving.Production for a seven day around the clock facility is normally handled in

five/eight hour shifts per week instead of the usual seven/twelve hour shifts per week. Skilled and unskilled labor is more efficiently utilized.

Recipes are standardized for batch preparation guaranteeing consistent high quality food product with optimal color, texture, moisture content and nutritional value.

2. Bulk Purchasing & Pre-PrepVolume purchasing and receiving dramatically reduces ingredient and

handling costs, and allows for a five day receiving schedule.As per scheduled recipes, ingredients are centrally prepared in advance.Ingredient quality and recipe consistency are maintained to extremely high

standards.

4. Non Pumpable Food PreparationCook Chill Tanks are designed for water bath cooking of vacuum packaged

meats, and other packaged food items.Low temperature cooking reduces shrinkage, increases tenderness and

retains natural juices and flavor.Upon reaching the desired temperature, hot water is automatically

exchanged for ice water, efficiently reducing food temperature below 40°F inthe fastest possible time. Programmable Time/Temperature controls allow for unattended overnight cooking.

5. Transfer & PackagingProduct Metering Filling Stations pump the cooked foods while still hot

(180°F), from Mixer Kettles and accurately meter them into flexible casings. The clipper and label dispenser are conveniently mounted on the cross bar

allowing the operator to seal, label and trim the filled casing in one swift motion.

The air operated piston pump has infinitely variable volume adjustment and a 2" delivery system allowing the pumping of virtually any product that will flow.

6. Tumble ChillingThe Tumble Chiller rapidly reduces the temperature of the filled casings with

a gentle tumble action in recirculating potable chilled water without productdamage.

The casings are loaded through an entry chute by hand or conveyor. Fully automated controls assure correct chilling in the fastest possible time for maximum refrigerated storage life.

Blast Chillers are also available to provide chilling for short term storage of products not compatible with water bath chilling methods.

7. Refrigerated StorageThe prepared and chilled foods are safely stored in low temperature walk-in

refrigerators at a temperature of 28°F to 32°F.Cook Chill food preparation allows for a safe refrigerated storage life of up to

45 days (depending on product). Menu items are now available for use on site,or to be shipped via refrigerated trucks or holding cabinets to remote serving points or satellite locations.

Not freezing the foods boasts many benefits; dramatic energy savings, thefreshly prepared qualities of food are maintained, and the nutritional attributes of food are not lost.

8. Rethermalization & ServingA wide variety of methods and equipment are available to heat the

preprepared food to a safe serving temperature.Convection Steamers, Kettles, Combination Steamer/Ovens, Tilting Skillets

and other conventional cooking equipment can be used to finish the product.Kettles and Skillets are used for hot water bath heating of multiple casings.

Convection Steamers and Combination Steamer/Ovens can be used for heating multiple casings or product emptied on to 2 1/2" solid pans.

3. Pumpable Food Preparation Cook Chill steam jacketed Kettles are designed and equipped for cooking a

variety of pumpable food products with qualities ranging from chunky to smooth.Horizontal, Vertical (Sweep Fold®), and Inclined Mixer Kettles are available for

mixing ingredients, maintaining product consistency and eliminatingburning/scorching.

Temperature controls, temperature chart recorders and automatic water cooling ensure the product is consistently cooked and cooled to your specifications.

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Cook/Chill Recipes

1. Central Planning/Scheduling

2. Bulk Purchasing & Pre-Prep

3. Pumpable Food Preparation

4. Non Pumpable Food Preparation

5. Transfer & Packaging 6. Tumble Chilling

7.Refrigerated

Storage

8. Rethermalization & Serving

• Health CareOperations

• School Food Service

• College andUniversityFood Service

• Restaurant Chains

• Correctional FoodService

• Military Food Service

• Supermarkets & Delis

• In Plant Service

• Transportation -Airlines, Railway

• Recreation - Hotels, Resorts, Amusement Parks

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When you select a Cleveland Systemyou are assured of receiving a completely integrated

system designed to meet you production goals.Our commitment to technical and operational support

guarantees maximum utilization and satisfaction.

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Cooking, Packaging & Chilling

Support Equipment

Rethermalization

Cook Chill Mixer Kettles - Horizontal, Vertical & InclinedThree styles of mixing kettles are available for your consideration. Each are capable

of cooking and mixing a variety of products with some or all or the following qualities: heavy, delicate, frozen, crisp, chunky, smooth, hot or cold. All have been

successfully used in the food production and processing industry for many years.

Pasta Kettles & BasketsDesigned specifically for cooking

pasta and pasta-like products. TheKettle is equipped with a large

overflow drain for rinsing the product.

Metering FillingStation

Designed to pumpcooked foods from MixerKettles and accurately

meter them into casings. The 2" discharge allows for

the pumping of chunkyproducts without damage.

Single & DoubleControl CentersControls the functions and

features of the Mixer Kettles andthe Pasta Kettles.

Steam BoilersNecessary whenever food

processing equipment requires direct steam for operation.

Available in electrically heated,gas or oil fired.

Condensing Units -Air & Water Cooled

Required for mechanical refrigeration of water in the IceBuilder by building ice around

the coils. The Condensing Unit s

capacity should be sized, based on building a full load of

ice within 16 hours.

Ice BuildersDesigned to provide a

continuous supply of ice waterto Tumble Chillers, Cook Chill

Mixer Kettles, Cook Chill Tanks, etc.. A pump circulates the icewater, when required, throughheat exchangers located in the

Tumble Chillers, Cook Chill Mixer Kettles, or Cook Chill Tanks. Each Ice Builder can

economically build ice for up to 24 hours a day.

Compressed AirSystems

A supply of compressed,dry, clean air is required tooperate major components used in Cook Chill Systems

(i.e. Tumble Chillers, MeteringFilling Stations, Clipper, the

Piston Valve on MixerKettles). Compressed AirSystems consist of an air

compressor and arefrigerated air dryer.

Hoist SystemsRecommended for lifting and

transporting large and heavyproduct loads from Cook Chill

Tanks, Pasta Kettles and Cook/Chill Mixer Kettles.

KettlesAvailable in over 60 different models, all

steam jacketed to cook quickly and evenlywithout sticking, burning or scorching.

Powered by either electric, gas or direct steam sources.

Heat water bath to 190°F and place casings into the Kettle for rethermalization.

Gently stir with a paddle to move theproduct in the casing for fast and even

heat-up time to 165°F.

Convection SteamersCleveland Convection Steamers offer acreative concept for preparing high

volumes of a variety of food products at an incredibly fast pace while maintaining a

very high quality standard.To rethermalize products simply place

casing into 2 1/2" deep perforated pan and heat to 165°F.

Combi-Oven SteamersThe most advanced family of

commercial cooking equipment availabletoday. Memory programmability stores

different recipes, making operation simple and fast for the operator.

To rethermalize products simply placecasing into 2 1/2" deep perforated pan

and heat to 165°F.

Tilting SkilletsCleveland Tilting Skillets are

designed for exceptional versatility by functioning as a Griddle, Frying

Pan, Kettle, Braising Pan, Steamer or a Bain-Marie.

Heat water bath to 190°F and placecasings into the Skillet for

rethermalization. Gently stir with a paddle to move the product in the casing for fast

and even heat-up time to 165°F.

ConveyorsDesigned for automatically transporting the Casing

packaged Food Products fromthe Metering Filling Station into

the Tumble Chiller.

Vacuum PackagingSystems

Packages avariety of products

in random sizesand widths for

cooking in a Cook Chill Tank.

Cook Chill TanksDesigned for water bath cooking of

vacuum packaged meats and otheritems. Low temperature cooking

reduces shrinkage, increases tenderness and retains natural juices and flavor. When the cooking processis complete, hot water is exchanged

for ice water for rapid cooling.

Tumble Chiller/Cook Tank Combination Units

Saves valuable kitchen space by combining two important functions into

one piece of equipment. During the day the Tumble Chilling method is

used to cool Kettle cooked products.During the night the combination unit can be utilized as Cook Chill Tank.

Tumble ChillersA mechanical rotating

machine used to reducetemperature of the casings

with a gentle tumbling action in recirculating icewater. Casings are loadedthrough the entry chute by

hand or conveyor.

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SOLUTIONSCleveland Range LLC. provides many of the operational solutions from Manitowoc, a global company dedicated to bringing

value to foodservice operators by equipping them with highly individualized real-world answers that enhance menus, service,

profits, and efficiency.

FINANCINGManitowoc offers low-rate, fast-approval financing on equipment from Manitowoc brands and on other equipment when

purchased with Manitowoc brands. Preserve capital, simplify budgeting, and get the equipment you need today, from

Manitowoc Authorized Dealers with Manitowoc financing.

SERVICECleveland Range LLC. products are backed nationwide by Manitowoc STAR Service. This network of certified service agents

provides fast response with factory-trained experts to assure your equipment will be fixed right the first time. Manitowoc STAR

service agents guarantee their work and use genuine OEM parts for best equipment performance and longer life.

To learn how Cleveland Range LLC. and other leading Enodis brands can equip you,or to apply for financing, visit www.enodisusa.com, consult your dealer, or call 727-375-7010.

©2006 Enodis plc except where explicitly stated otherwise. All rights reserved.

STEAMERS / COMBI-OVENS / KETTLES / BRAISING PANS / ROTISSERIES / COOK CHILL SYSTEMS

Ph: 1-800-338-2204 /Web: www.ClevelandRange.com / Email: Steam@ClevelandRange.com

CC4PC 0309

Experts in Steam Cooking

PRE-SALES SUPPORTOperation & Management Specialists are available for project &menu evaluation to make recommendations for the facilitylayout and equipment sizing.Factory Engineers/Specialists are available to assist the foodservice design consultant:• Specific shop drawings are provided which includedimensions, utility connection points, required clearances, etc.

• Typical Cook Chill Systems schematic drawings for piping &wiring are provided.

• Factory Engineers can check the drawings for accuracy andmake recommendations for changes if required.

PRE-START-UP SUPPORTGuidelines for Cook Chill recipe development and HACCP areprovided by our Operations Specialists/Registered Dietitians withemphasis on recipe development for your specific operation.Prior to installation of the equipment a Factory Specialist isavailable to meet with the food service consultant and theinstaller to inspect the job site and to review the installationdrawings with the installers.

After the installation has been completed:• A Factory Specialist is available for inspection of both theinstallation and operation of the equipment. Before theinstallers leave the site recommendations for installationchanges are made if required. Calibration of the productionequipment is completed at this time.

• In-house maintenance personnel can be trained during start-up, in the care of the equipment and preventativemaintenance.

• The Local Cleveland Authorized Maintenance and RepairAgency will also be available for technical assistance. The localagency will carry spare parts and is factory trained andcertified prior to start-up.

ACTUAL START-UP with food production and staff trainingTraining will be provided by our Operations Specialist withemphasis on:• Food Sanitation & Handling • Operation of the Equipment •Recipe Implementation • Food Production

• HACCP and Quality Assurance Guidelines

SITE VISITS & FOLLOW-UP TRAINING can be scheduled toreview and reinforce information.

WARRANTYAll materials and workmanship is warranted for one completeyear.

CLEVELAND RANGE COOK CHILL ADVANCED FOODPRODUCTION SYSTEMS ARESUPPORTED BY:• Operators Manuals • Administrative Procedure Manuals •Service Manuals • Cook Chill Kettle recipes • Cook Tank recipes •On-site training of the in-house maintenance personnel • ChilledFood System Guideline Manual • AutoCad drawings • Operatortraining and follow-up site visits

Cook Chill System Support