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The theory behind cook-chill is actually pretty basic -- cool hot food through the bacterial danger zone (140 deg F. to 41 deg F.) quickly (90 minutes or less) and uniformly. Once chilled, food products can be stored in standard walk-in coolers at 34 deg F. When ready to serve, operators merely rethermalize the needed items.
The development of HACCP (Hazard Analysis Critical Control Point) programs has only served to heighten the already growing popularity of cook-chill production. Quick chilling greatly reduces the chance of a foodborne illness outbreak.
Quick chillers come in two basic types: blast and tumble units. When employing the tumble chill method of production, product is first cooked and then pumped still hot into plastic casings, which after being sealed, are "tumbled" in an icy bath. Operators use tumble chill equipment to cool soft or semi-soft, kettle-made products. These products' shelf life can run from 21 to 45 days.
Blast chillers, armed with heavy-duty components and featuring larger compressors for greater power, use high-speed fans to circulate refrigerated air and uniformly cool food produts. Pans inside a chiller can usually be brought down from 160 deg...