The escalating energy crisis throughout South Africa has seen food producers who manufacture to order being hit hard by current load shedding power outages. Unable to deliver full orders, they need to turn to technology which can assist them greatly with maximising their production in the current disruptive ‘load-shedding’ environment.
With the DC Norris Cook Chill system in place, these customers insure against short delivery, and maximise their production by holding more “back-up” ready to pack product in their chillers. Packing lines generally consume less energy than cooking lines, so DCN customers can keep packing/dishing on generator power and continue to fulfil the daily orders they get from their retail customers.
Whilst most manufacturing facilities have generators as back-up, the cost of running them to keep the full factory going is becoming prohibitive. If the customer using the DCN Cook Chill method can cook on ESKOM power and store larger quantities for later distribution and packing, this dramatically reduces their costs.
Here we examine how DC Norris’ Cook Chill Technology and expertise can assist African food manufacturers in the current climate.
DCN has an esteemed history working with manufacturers who may be delivering meals from 50,000 up to 500,000 meals per day for major retailers, airlines, hospitals, schools, wholesalers and restaurant groups. Productivity and efficiency are paramount, and they understand the importance of investing in reliable top quality food processing equipment.
In the 1980’s, David Norris was instrumental in presenting the Capkold Cook Chill Concept to the fast-growing market for Ready Meals in the UK and Europe. Foods such as soups and sauces are cooked to a high temperature before being sealed in plastic pouches. Products are then rapidly chilled within the pouch, before being placed in chilled storage at below 4◦C. Cooking through the ‘danger zone’ 5-63◦C (40-145◦F) and then rapidly cooling slows spoilage caused by microbial growth. The high temperature of the product also pasteurises the inside of the pouch automatically during the filling process.
For the first time ever food manufacturers could benefit from a chilled shelf-life of up to 45 days and allowed them to build up a stock of quality food for future use. Capkold also improved distribution and gave manufacturers the flexibility to transport foods from centralised kitchens to serving outlets or supermarkets in a safe sealed environment. Once opened, the pouches would have the standard five to seven days refrigerated shelf-life.
The finished product is also improved and of a consistent high quality with both large and small particulates processed without damage. The flavour, texture and aroma of fresh ingredients are retained during the process passing on the benefits to the end consumer.
Since those early days, DCN has continued to bring new developments to the industry to make food processing more efficient in today’s world. Innovations such as DCN Jet Cook have made production even faster and improved the nutritional value of pre-prepared meals. The Company have also recently re-designed their Tumble Chiller to make it even more energy-efficient and water saving.
DCN Cook Chill System Process
The Cook Chill process follows a logical fully documented production cycle, which is controlled using our Recipe Manager Software which creates ingredient listings, step–by–step procedural processes and user access security with all recipes stored to a relational database. The system maintains full records of kettle yields, cooking times and temperatures allowing bar code identification from preparation through to packaging to ensure all HACCP controls are met.
1.Cooking
DCN’s Steam Jacketed Kettles with Jet Cook Technology. Different models and sizes are available depending on the customers required throughput – from 300-3000 litres. Systems are available with a range of accessories depending on the product. These include Braising Bar Technology, In-Vessel Homogenisers and Vapour Reduction Systems.
2. Packaging
A DCN Pump Fill Station transfers food at 85-95◦C into multi-layer pouches which are then clipped.
3.Chill
Pouches are conveyed into a DCN Tumble Chiller or the new energy and water efficient Belt Chiller where they are gently circulated and massaged in chilled water to rapidly drop the temperature from 95◦ to below 5◦C.
4. Chilled Storage
Clipped pouches are placed in chilled storage at 2-4◦C where it can be stored safely for up to 45 days.
5.Heating and Serving
The pouches can be transported to various locations such as multiple restaurant/hotel sites, where they can be reheated and served. Alternatively, they may be destined for a supermarket shelf, so pouches can be emptied into a depositor and portioned on a filling line into packaging before being delivered to the outlet.
DCN has installed Cook Chill Systems for African customers and global brands who are supplying the major supermarkets throughout the Continent with long shelf-life chilled convenience meals – from soups and curry sauces to ready meal components such as bechamel and bolognese.
The equipment can be customised to meet the specific needs of manufacturers and tailored to the unique characteristics of products, shift patterns and production schedules.
DCN has a Product Development Kitchen in South Africa at the Cape Town Peninsula University and can also assist African manufacturers remotely.
