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Design Excellence : Cool Technology

Guide to Cook-Chill
Easy as 1-2-3
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WILLIAMS - YOUR FIRST CHOICE


Williams Refrigeration is the market With extensive manufacturing Williams is a truly international
leading manufacturer and provider of facilities in the UK, Australia and company with global capability
quality refrigeration solutions meeting China, Williams has built a global and an outstanding reputation for
commercial catering and foodservice reputation for performance and innovation and excellence.
requirements worldwide. reliability of its wide range of high
Our commitment to our customers
performance cabinets, counters,
For over 30 years Williams has is absolute. Not only do we offer the
blast chillers and freezers,
been producing high quality, award widest product range on the market,
coldrooms, merchandisers and
winning professional refrigeration but also provide specialist help and
bakery equipment, all carrying ISO
equipment exceeding international advice on choosing and installing
standards of quality and design.
quality and performance standards. the right equipment through our
technical and after-sales support
offering a total solution for any
refrigeration requirement.

INTRODUCTION
Advances in technology means that We continually invest in product Health Cook-Chill/Freeze Guidelines.
catering establishments of all sizes design and development to bring
The purpose of this guide is to
and types can now benefit from you the highest quality engineering
explore some of the many myths
using Cook-Chill systems. performance and reliability.
that surround the Cook-Chill system,
Williams Refrigeration, the market Using the latest control systems while at the same time providing an
leader in refrigeration technology, is and technology, Williams range of accurate description of its operation
leading the way, producing compact, Blast Chillers, Chiller Freezers and and the benefits it can bring to your
yet sophisticated equipment that Freezers are all driven by our unique business.
suits your needs and your pocket, Simple to Use 1-2-3 Control Panel
As you will see in the following
with simple to use controls. featuring the 3-step operation that
pages, Cook-Chill systems can
all staff will find easy to operate
In the past, only large catering save you time, money and also
within only a few moments of basic
operations were able to take help increase your turnover and
induction. In fact, many users need
advantage of Cook-Chill systems profitability. What’s more, your
no induction at all – it’s that Easy!
which, because of their size, were Environmental Health Officer will be
often thought to be very complicated. In a fast moving world with happy, letting you get on with your
In fact, the system is quite simple increasing caution over food hygiene business.
and uses much of the equipment you you can be assured that in Williams
We hope that you find this guide
will already have in your kitchen. you have quality, performance,
useful and informative.
accuracy and reliability for your
At Williams we lead the way in
product and business. The range
manufacturing and marketing Blast
of Williams Blast Chillers, Chiller
Chilling and Freezing systems
Freezers and Freezers will help you
worldwide.
to show due diligence and comply
From the smallest caterer to the fully with UK and International Food
largest production unit, whether on Safety Regulations and Hygiene
land or at sea, Williams provides the Guidelines such as the Food Safety
innovation and flexibility to answer Act and Food Hygiene Regulations
your needs. – HACCP (Hazard Analysis Critical
Control Point) and the Department of
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COOK-CHILL EXPLAINED...
What is Cook-Chill Who uses Cook-Chill Will my business benefit
Cook-Chill is a simple, controlled Systems? from Cook-Chill?
system of advanced food preparation
Thousands of establishments While Cook-Chill is commonly
designed to provide more flexibility in
throughout the whole spectrum of associated with institutional catering,
foodservice. The technique involves
the Catering Industry use Cook-Chill no catering operation is too small to
the full cooking of food, followed
systems. adopt a Cook-Chill system. If your
by rapid chilling and storage at
business is serving hot meals and
controlled temperatures (for up to Anyone who has eaten at a top
is one of the following, then you will
five days). When required, the food restaurant or hotel, at a banquet or
almost certainly benefit:
must be regenerated before service. reception, or on an aeroplane or ship is
The production system itself is likely to have eaten a Cook-Chill meal. • Hotel
simple to operate if well managed, Cook-Chill systems are also used by • Pub
and completely safe provided the many institutional caterers such as • Restaurant
Department of Health Guidelines on hospitals, universities and in much of • B&B
temperature/time controls are followed. Armed Forces catering. The largest • Fast food restaurant
Cook-Chill user is the housewife • Care home
Cook-Chill Systems have the
buying a wide selection of chilled • Contract caterer
added benefit of maintaining food
ready meals to take home from the • Bakery
quality, nutritional value, flavour and
supermarket. • Staff restaurant
appearance.
• Institutional caterer
Installing a Cook-Chill System also • Cafe/bistro
offers the caterer added flexibility • Travel caterer
and management – and of course • Meals on wheels
profitability! • Pizzeria
• In-flight catering
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POTENTIAL PROFIT INCREASE UP TO 28% THROUGH


HIGHER PRODUCTION CAPACITY, MEAL TURNOVER
AND REDUCED FOOD WASTAGE

• Hospitals Why do caterers use Blast Avoid the risks of food


• Universities Chillers/Blast Freezers? poisoning – control bacteria
• Armed forces catering
• Government
The principle feature of Blast Chillers, growth
Blast Freezers or Blast Chiller Freezers
• Local authorities The very young and elderly are most
is that they are capable of rapidly
at risk from food poisoning, however
reducing the temperature of hot foods
For large and small establishments everyone can be affected and litigation
(+90ºC) to low, safe temperatures
the principles and advantages of and prosecutions are on the increase.
(+3ºC or -18ºC). Therefore, they make
the system are the same. The only Bacteria divide in two every 20 minutes
it easier for caterers to comply with
difference is that small to medium and in 12 hours one bacteria multiplies
Food Safety and Temperature Control
sized operations do not have to invest to become almost 69 billion bacteria.
Legislation. In fact, many caterers are
in equipment designed to deal with With a proper Cook-Chill System and
using them solely for that purpose,
volume. Williams Blast Chillers you can take the
and in doing so are performing a very
risk out of your operation.
For the simplest Cook-Chill system, simple Cook-Chill operation.
all that is required in addition to the
cooking equipment you already have
Nevertheless, only using a Blast How quickly will I be able to
Chiller to cool cooked food rapidly for
is a Blast Chiller, Chiller Freezer or
immediate or same day service, is not
recover my investment?
Freezer, a suitable storage area such
making the most of the equipment. Your business will be able to
as a refrigerator (at +3ºC) and an
Williams Blast Chillers and Freezers immediately recover a portion of your
understanding of the guidelines to
can also be used as short term storage labour costs, reduce waste, maximize
Cook-Chill/Freeze systems.
cabinets too. efficiency and increase turnover, which
accelerate your ability to recover your
investment.
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THE TRUTH BEHIND COOK-CHILL


The use of Cook-Chill has no
limitations. Any meal can be prepared,
99 The equipment is large Is simple to operate
cooked, chilled, and refrigerated with and expensive.
little or no nutritional or quality loss, The equipment required by Is profitable
and without altering its appearance. hospitals and local authorities
which produce high volumes of
There are several misconceptions:
food is large and can therefore
Reduces food wastage
be expensive. But this is not the
99 Cook-Chill is dangerous case for small to medium sized Is time saving
because it is difficult to establishments. Many of these
use. caterers will already have suitable
Can help improve your
ovens and storage facilities, so
There is no known case of business
they will only need to acquire a
someone suffering from or dying
blast chiller.
as a result of eating a properly
prepared Cook-Chill meal.
99 It is an insult to the Makes it easy for you to
Unfortunately, many people have comply with Food Hygiene
suffered food poisoning and have skill of the professional
died from eating conventionally caterer. Regulations.
produced food that has not been
Cook-Chill gives you more time to
prepared or stored properly while
utilise your skills more effectively
using traditional methods.
than any other method.
99 Cook-Chill is only for Instead of spending valuable
mass catering. time on mundane tasks, the
professional caterer can use that
No; it can be used by restaurants,
time to improve presentation,
clubs and even fast-food
create new dishes and menus,
operations.
and attend to all other things that
make a successful business.
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ADVANTAGES OF COOK-CHILL
Suitable for any foodservice Menu extension Increased profitability
operation The flexibility of the system allows All of the above can make your
you to prepare a greater selection operation more efficient while offering
The system can be utilised effectively
of dishes, offering your customers customers greater choice and better
by establishments of any size or type.
more choice while still maintaining service. You will be able to cope
or, improving on quality. In addition, with larger numbers of customers
Effective time management because you are preparing meals in and at short notice. This will result in
and control system advance you can afford to take time increased turnover and profitability.
The system allows caterers to better and make fewer mistakes. You should be aware, therefore, that
organise their time and that of their you may, eventually, have to extend
staff. Prime cooking can take place No modification of recipes your washing up facilities to cope with
when the business is quiet, for A Cook-Chill system allows you to the extra business.
example, leaving less to do when you use all your favourite recipes without
have customers to attend to, while at alteration. Fantastic opportunity for
the same time providing a safe and
controlled environment and system of Flexibility in service expansion
If the meal turnover of your business
work. Because all dishes only require simple
is limited by the number of meals you
regeneration before service, caterers
are presently able to cook and serve
Effective resource can serve a wide variety of food all
with your existing kitchen, Cook-Chill
management day and can easily cope with the
is a fast way to increase your capacity
fluctuating numbers of customers
Labour and equipment can be used without necessarily expanding your
throughout the day.
more efficiently while ingredients kitchen or employing extra kitchen
can be bought in larger quantities, staff.
providing economies of scale. You
Reduced food wastage and
could also prepare meals for several improved portion control
establishments from one kitchen. Portions can be made up precisely
and only the meals ordered will need
Improvement in service to be regenerated. This means little or
Because most food will be prepared no wastage for you.
in advance, the caterer will have more
time to improve on presentation and
attend to customers.
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THE COOK-CHILL SYSTEM


It is easiest to view a Cook-Chill system
What you will need as a series of stages. Each of these
If you are already serving hot food,
stages should be regarded as equally
the only additional equipment you will
important to guarantee safety, and
require for a small to medium sized
good quality dishes.
Cook-Chill operation is a suitable
Blast Chiller or Chiller Freezer. You will 1. Selection of raw materials
also need a suitable refrigerator or
2. Storage of raw materials
coldroom (0ºC/+3ºC) for the storage
of the finished product. 3. Preparation
As with any cooking operation, a 4. Cooking
Cook-Chill system requires care to
5. Portioning (Hot)
ensure that food does not become
vulnerable to harmful bacteria. Staff 6. Rapid Chilling or Freezing
should, therefore, be given specific
7. Storage of chilled foods
training on the Cook-Chill operation,
in addition to basic Food Hygiene 8. Distribution of chilled foods (If
training. Williams Refrigeration and its applicable)
dealers are able to help you with this.
9. Regeneration (Reheating of food)
10. Service
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FOOD SERVICE OPERATION : HOW DOES IT WORK?

Purchase of Ingredients

Receipt of Ingredients

Storage (Ambient, Chilled, Frozen)

Preparation

Cooking

Hot Portioning

Blast Chilling +90 to +3°C Blast Freezing +90 to -18°C

Hard Soft Frozen Storage (-18°C)

Cold Portioning

Chilled Storage (+3°C) Contolled Thaw (+3°C)

Chilled Portioning Chilled Portioning

Regeneration Regeneration

Service
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HOW IT WORKS
In order to make chilling more efficient
1. A selection of raw after cooking, joints or packs of meat
6. Rapid Chilling or Freezing
materials Whatever the type of Blast Chiller
should not weigh more than 2.5kg,
you Whatever the type of Blast Chiller
Poor quality raw materials are not or measure more than 100mm in
or Chiller Freezer you use, it must
going to improve with cooking. It is thickness. For dense foods such as
be capable of chilling the hot food
vital, therefore, that you ensure your meat sauce based dishes - lasagne,
to between 0°C and +3°C within
supplier only supplies you with high moussaka, shepherds pie or stews (or
90 minutes of placing it in the Blast
quality products and, if necessary, even mashed potato) we recommend
Chiller and commencing to chill. This
check their storage, handling and no more than 50mm thickness, as
is not only to ensure safety, but also
distribution methods. described in the Department of Health
preserves the appearance, texture,
Cook-Chill/Freeze Guidelines.
flavour and nutritional value of food.
2. Storage of raw materials Your Blast Chiller or Chiller Freezer
It makes sense to keep good quality 4. Cooking should be equipped with a food probe
raw materials in safe storage and Whatever the food product you are
or probes with which you can monitor
in prime condition before they are cooking and by whatever method, it
the temperature of the food.
needed. This means following basic is essential that the core temperature
Food Hygiene and HACCP principles of the food reaches at least 70°C, and Large joints of meat etc, may not chill
for food storage to ensure the raw is held at this temperature for at least as quickly as first required. In this case,
products are stored at the correct two minutes. This is to ensure that any the temperature of the joint must be
temperature and humidity levels. pathogenic micro-organisms that may reduced to +10°C or below within 150
be present are destroyed. (Check the minutes, and then portioned before
3. Preparation accuracy of all thermometers used, final chilling to between 0°C and +3°C.
At the preparation stage, basic Food every three months and recalibrate
Every dish has its ideal cooking
Hygiene Regulations and HACCP if necessary). You should not find
method to suit its density or structure,
Guidelines apply. Separate surfaces/ it necessary to alter your traditional
this applies to Blast Chilling too. It
areas and separate implements should recipes for a Cook-Chill system.
is important to have the options of
be used for the preparation of certain
Hard or Soft Blast Chilling available
products such as raw fish, meat and 5. Portioning to ensure food is not damaged in the
poultry to prevent cross-contamination Once the food is cooked, the
process and the quality is maintained.
and spread of bacteria. chilling process must start as soon
as possible, and at most within 30 Hard Blast Chill - during the 90
Ideally, food preparation should take
minutes. minutes the air temperature in the
place in an area separate from the
cabinet drops below freezing point.
cooking and portioning - as outlined in This leaves time for hot portioning prior
the HACCP Guidelines. to chilling. However, handling of food This is designed for dense, large
should be kept to a minimum. products, which are difficult to chill
If some raw materials arrive in a frozen
and have a higher fat content such
condition, they should be thoroughly Dishes can be assembled from
as meat based sauces, meat joints,
and safely thawed before use. individual components after chilling.
mashed potato and lasagne. The air
Usually, the ideal containers for chilling
We recommend a controlled thawing temperature of the cabinet ensures the
food should be no more than 50mm
cabinet for this purpose. Rapid high product reaches the required +3°C
deep. Note: Some containers are
temperature thawing can encourage within the 90 minutes without the risk of
made of materials which can insulate
freezing or damaging the food.
the growth of pathogens and may the food, thereby affecting chilling
leave cold spots at the core of the times. Covered containers and vacuum Soft Blast Chill - During the 90
food. For this reason we do not packages can also increase chilling minute process the air temperature
recommend thawing products with times. remains above 0°C. This is ideal for
a microwave oven unless the oven is delicate and light products such as
If disposable containers are used, it is
specifically designed to ensure even fish, rice, vegetables, cream, desserts,
essential that they have been stored
thawing. cakes and fried foods. The soft blast
under hygienic conditions.
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chilling cycle gently reduces the alarms which will alert you should should be consumed within 30 minutes
product temperature to +3°C in the temperatures, for any reason, rise of removal from storage.
required 90 minutes with no risk of above the recommended levels.
If the food is to be regenerated, this
damaging the delicate product.
Chilled food may be kept under the should start no more than 30 minutes
The speed at which chilling takes above conditions for up to five days after the food is removed from chilled
place will be affected by the shape, (including production and regeneration storage. Regeneration must take place
size and density of the food, its days). To ensure that products do close to the point of consumption.
moisture content, heat capacity and not exceed this time span (and are
Suitable reheating equipment,
entry temperature. Placing lids on therefore not wasted), a system of
recommended in the Department of
containers or stacking them on top of stock rotation should be employed.
Health Guidelines, includes infra-red
one another, will increase the chilling One method is to use colour-coded
units, forced air and steam convection
time required. However, covering food labels, a different colour for each day
ovens and special chill/regeneration
can protect against contamination, and with a ‘use by’ date, production date
trolleys. Hot-air oven may be used, but
is therefore sometimes appropriate as and product description marked on
you must ensure that exposed areas of
long as chilling can still be achieved each label. A ’first in, first out’ policy
food do not become dehydrated.
within the required time limits. should be used. If, for any reason, the
food (in store or during distribution) Commercial microwave ovens may be
It is also at this stage that you would
reaches a temperature over +5°C but used, and we recommend these for
choose to Blast Freeze the product
no more than +10°C, the food should the regeneration of individual portions
ready for storage in a frozen food
be consumed within 12 hours. or small numbers of meals. Ideally,
cabinet for several weeks or months at
of course, it is preferable to install
below -18°C. Should any food in the store exceed
purpose-built regeneration equipment.
its expiry date or reach a temperature
Williams Reach-in equipment offers
over +10°C, it should be destroyed In order to ensure the destruction
Blast Chilling or the dual function of
immediately as it will be unfit and of any pathogens present, the core
Blast Chilling and Freezing – taking the
unsafe for consumption. temperature of the food must reach
core temperature of the product from
at least +70°C, and be held at this
+70°C to -18°C within the guideline
time of 240 minutes (4 hours). The
8. Distribution temperature for at least 2 minutes. To
check that this temperature has been
Blast Freeze cycle (see graph - page If you intend to operate a centralised
reached, insert a core food probe
15) transforms the liquid present in Cook-Chill system and supply food to
thermometer into the slowest heating
the food into microcrystals which do one or more other locations, the dishes
point (usually the centre).
not damage the tissue structure of the must be transported to the other site
product and ensures the quality of the whilst in their chilled state (kept below Any food that has been regenerated
food is maintained so you still have a +5ºC). The use of refrigerated vehicles and allowed to cool should be
high quality product after thawing. is recommended, or at the very least, destroyed immediately. Any
pre-chilled insulated containers for regenerated meals not consumed
7. Storage of chilled foods short journeys. must be destroyed and never be
reheated or returned to chilled storage.
CChilled food should be stored in a If chilled food is being transferred
dedicated refrigerated storage cabinet to other sites, it must not only be
at a temperature of between 0°C and transported at the correct temperature,
10. Service
Once food has been regenerated to
+3°C, in order to control the growth of but on arrival, it must also be placed
the required temperature, it should
micro-organisms. in appropriate refrigerated storage
be consumed as soon as possible,
cabinets (+3ºC) until required.
You should use a refrigerated cabinet and preferably within 15 minutes of
or coldroom designed for chilled food regenerating. The temperature of the
storage, and use it solely for your
9. Regeneration food should not be allowed to fall
Cook-Chill products. Williams storage Cooked and chilled foods that are to below +63°C.
cabinets and coldrooms feature be eaten cold or at room temperature,
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Advanced Air-Flow technology Food Probe

WHY BUY WILLIAMS


Williams Refrigeration has over 30 temperature is too high or too low or • As with all Williams equipment,
years experience in designing and the cabinet is not functioning Blast Chillers, Chiller Freezers and
manufacturing Blast Chillers. During Freezers are 100% CFC free and
• Range of models to suit all types
this time, we have built a worldwide manufactured to meet or exceed
of requirements and environments.
reputation for outstanding quality international build quality and health
Most models are designed for 43ºC
and performance of our Blast Chiller and safety standards including
ambient environments
equipment and the leading technology ISO9002 and CE
used in the control panel to ensure • Advanced air flow design for
• Reach-in Blast Chillers and Freezers
ease of use and accuracy. uniformity of chilling/freezing of
can also be built to meet marine
product load and eliminate the risk
specifications and include positive
Key Features and Benefits of of dehydration and damage by large
latch handles, marine voltages,
Williams Blast Chillers, Chiller ice crystals ensure excellent product
flanged legs for deck fixing and
quality every time
Freezers and Freezers bulkhead fixings
• All models feature stainless steel
• Curved, sleek looks with excellent • Selected models comply to ETL/UL
exterior and interior with easy to
functional hygienic design including Approvals for USA
clean, hygienic interiors including
Williams unique simple to operate
removable racking/shelving on
1-2-3 control panel and easy to read
reach-in cabinets.
Options include:
digital display – simple for all staff
• UV lighting on Roll-in models for
to understand, use and control the • Auto defrost on completion of every
additional hygiene safety
Blast Chill cycles - designed for cycle and every six hours to ensure
accuracy, flexibility and control continued operational efficiency • Historical hard data printer option
available for Blast Chill/Freeze
• All models fitted with high quality • Coated evaporator and coils
cycle recording. Graphical print
‘L’ shaped core food temperature for enhanced life and hygiene
out at the end of each Blast Chill
probes compliance
cycle showing the time of cycle and
• Operating the Blast Chill cycle using • All models automatically switch to temperature fall
the food probe ensures perfect storage mode at the end of each
• Available for multi-voltages to suit
temperature control every time and Blast Chill cycle for holding product
international requirements
removes any uncertainties from the at the right temperature until you
Blast Chilling/Freezing process are ready to move it to the correct • Roll-in models offer the option of
storage cabinet or coldroom Williams unique storage “pod”
• Audible alarm sounds at end of
refrigeration system which offers
Blast Chill or Freeze cycle to notify • All models compatible with range of
increased efficiencies and storage
staff – hi/lo and fail safe alarms will temperature monitoring and control
area
also sound to indicate if product systems available from Williams
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EASY AS ONE-TWO-THREE
Operating Williams Blast Chillers and During the Blast Chill cycle using the
Freezers is as simple as 1-2-3. With a
Food Probe Control* food probe the LED display shows the
choice of operating the Blast Chill or Press to select Blast Chill or time elapsed so you can clearly see
Freeze cycle using three buttons or Blast Freeze cycle Press to how long the product has been Blast
with the food core temperature probe select Hard or Soft or Blast Chilling and the core temperature of
or probes Freeze cycle the product.
Press to select food probe The time elapsed feature is unique to
Control Buttons and ensure the probe or the Williams range of Blast Chillers and
Press to select Blast Chill or probes are placed in the Freezers. The first window will show the
Blast Freeze cycle (on Blast centre of the products time lapsed and the second window
Chillers – chilling is the only requiring chilling will show the core food temperature(s).
option) Press to select Hard
Press to start cycle Once the cycle is complete the Blast
or Soft Chill or Blast Freeze
Chiller, Chiller Freezer or Freezer
(on Blast Freezers – Blast * Not recommended for
will go through an auto defrost and
Freeze is the only option) freezing
automatically switch to storage mode
Press to select time options to ensure the food is kept at a safe
30, 60, 90, 240 minutes temperature of +3ºC or -18ºC until
and food probe (depending you are ready to transfer the load to
on the size of load and the correct storage cabinet/coldroom/
product) freezer room.
Press to start the Blast Chill
or Blast Freeze cycle
If you have made a mistake
press and start again
During the Blast Chill/
Freeze cycle the cabinet
temperature will be shown
throughout the process
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CHOOSING THE RIGHT BLAST CHILLER FOR


YOUR OPERATION
To find out which model is the most if the storage temperature reaches
suitable for your operation, consider
Storage equipment unacceptable levels. A temperature
The storage equipment used for
the type of food you will be blast recording device is also required.
holding pre-cooked chilled foods must
chilling or freezing, as well as the
be designed and used specifically for When selecting storage equipment,
volume of food you need to produce,
that purpose. Williams cabinets are allow for sufficient capacity to cope
calculated in quantity of kilograms.
equipped with shelves or gastronorm with peak production, as well as room
When calculating volumes remember tray slides. An ordinary non- for an efficient stock rotation system. A
that you may be producing meals for gastronorm commercial refrigerator minimum storage capacity of two days
consumption over seven days but with that is in general use within the kitchen is normal for Cook-Chill products.
production in only five days. It is also is not usually suitable.
Storage equipment will need to be
wise to allow a little extra capacity
Steps must be taken to ensure that sited in an area that allows for easy
than you require at the present time, in
possible cross contamination between access, and must be sufficiently close
order to allow for the expansion of your
raw foods or other cooked products to the Blast Chiller to ensure that food
business and changing menus.
and stored chilled food does not occur. arrives at the store without risking any
fluctuations in the 0ºC/+3ºC chilled
The store must be capable of holding
temperature - whilst still at the optimum
products at a constant temperature
chill temperature.
of between 0°C and +3°C, and this
should be indicated clearly by a visible IMPORTANT! make sure your cooking,
temperature indicator. chilling and storage equipment are all
compatible with the containers you use
The equipment should ideally feature
(Gastronorm or designed for Combi
an audible alarm which will alert you
ovens).
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PRACTICAL EXAMPLE
In this example, the owner of a The restaurateur worked out that by The machine chosen has plenty of
business in a busy holiday resort, installing a Blast Chiller capable of spare capacity to cope with the future
serving 600 meals per week over six chilling 175 meals per day he could expansion of the business, which
days (50 covers, two sittings and a reward his staff by giving them may include extending the present
turnover of one per sitting), realised weekends off, prime cook on only restaurant or setting up an outside
that there was potential to operate at four days per week starting at 8.00am banqueting service to supply hotels
the same daily turnover on a seven day and increase his meal turnover by 100 and weddings in the area. In addition,
basis. meals a week without incurring any a chilled food cabinet was purchased
additional staff or premises costs. solely for the storage of the blast
However, the reputation of the
chilled food.
business was due, in large, to the A production schedule (below) was
quality of the staff who were given drawn up based upon a turnover of As a result of installing the Blast Chiller
Mondays off in lieu of weekends. The 100 meals per day, cooking on four the restaurateur in question was able
option of employing extra part-time days. to achieve a 28% increase in net profit
staff for Mondays only would wipe out as illustrated by the following figures:
The machine he selected was a
the advantage gained. In any case,
WBCF30. The machine is actually
skilled staff were almost impossible to
capable of chilling 335 x 340g portions
find.
per day based on five 90 minute
Meanwhile potential customers were cycles of 30kg per day. Of course, a
being turned away to the advantage of greater number could be achieved if
other establishments. There had to be the machine were used more times per
another solution. day.

£500,000 Profit and Loss With Blast Chiller Without Blast Chiller
Turnover £472,000 £405,000
Staff Wages (£59,520) (£59,520)
Raw Materials (£157,500) (£135,000)
£250,000
Other Expenses (£58,000) (£57,000)
Gross Profit £196,480 £153,480
Less Tax (33%) (£64,838) (£50,648)

Turnover Costs Gross Profit Net Profit £131,642 £102,832


*Average price of meal is £13.50

Without Blast Chilling Store Cook Serve Balance With Blast Chilling Store Cook Serve Balance
Monday 0 0 0 0 Monday 0 175 100 75
Tuesday 0 100 100 0 Tuesday 75 175 100 150
Wednesday 0 100 100 0 Wednesday 150 0 100 50
Thursday 0 100 100 0 Thursday 50 175 100 125
Friday 0 100 100 0 Friday 125 175 100 200
Saturday 0 100 100 0 Saturday 200 0 100 100
Sunday 0 100 100 0 Sunday 100 0 100 0
www.williams-refrigeration.co.uk

BLAST CHILLER TIMES


Approximate times taken to chill
different foods by various Williams Food Temp
+90°C
Blast Chillers
Air Temp
Please note that actual times will
depend on the thickness of the
product, type of container, actual entry
temperature and ambient temperature.
Different food types chill at different Temperature°C
rates. If trays or trolleys are loaded with
different types of product they will chill
at different rates and times will differ.

+0°C
Time (Mins) 90mins

MEAT Hard Blast Chill 40 - 90 mins depending on type, size and quantity (Includes beef, pork, lamb,
poultry pieces, stock and mince)
FISH Soft Blast Chill 30 - 90 mins depending on type, size and quantity (Includes fish, e.g. haddock,
plaice, cod fillets, salmon, shellfish, - fried, poached or baked)
PREPARED DISHES Hard Blast Chill 50 - 90 mins depending on type, size and quantity (Includes meat based stews,
casseroles, lasagne, moussaka, shepherds pie, mashed potato, risotto)
VEGETABLES/PULSES Soft Blast Chill 30 - 90 mins depending on type, size and quantity (Includes carrots, all green
vegetables, cauliflower, rice, sliced potatoes, - steamed or roasted)
FRUIT Soft Blast Chill 60 - 90 mins depending on type, size and quantity (Includes stewed apple,
peaches, cherries, rhubarb and other cooked fruits)
DESSERTS Soft Blast Chill 30 - 90 mins depending on type, size and quantity (Includes fruit based desserts,
cream based, egg cuWstards, flans and pies)
Hard Blast Chill 30 - 90 mins depending on type, size and quantity (Includes steam puddings,
sponge cakes, dense desserts such as tiramisu, cheesecake)
VACUUM PACKED SOUPS/SAUCES Hard Blast Chill 75+ mins (depending on type, size, quantity and packaging) (Includes all types of
(max 4kg) soup, custard, sweet and savoury sauces)
NB: The type of packaging will affect the Blast Chilling time and in extreme circumstances may
take longer than 90 mins
BAKERY PRODUCTS
Cakes Hard Blast Chill 30 - 90 mins depending on type, size and quantity
Cream Cakes/Gateaux Soft Blast Chill 50 - 90 mins depending on type, size and quantity
Pastry Hard Blast Chill 60 - 90 mins (pies, flans) depending on type, size and quantity
www.williams-refrigeration.co.uk

BLAST FREEZER TIMES


Approximate times taken to freeze
different foods by various Williams Food Temp
+90°C
Blast Chiller Freezers and Freezers
Air Temp
Please note that actual times will
depend on the thickness of the
product, type of container, actual entry
temperature and ambient temperature.
Temperature°C

Different food types freeze at different


rates. If trays or trolleys are loaded
with different types of product they will
freeze at different rates and times will
differ.

+0°C
Time (Mins) 90mins

-15°C

MEAT Blast Freeze 60 mins up to 240mins (all types of meat product)


FISH Blast Freeze 60 mins up to 240 mins (Raw fish/cooked shellfish)
PREPARED DISHES Blast Freeze 90 mins up to 240 mins (Meat based dishes, mashed potato)
VEGETABLES/PULSES Blast Freeze 60 mins up to 240 mins (Fried potatoes, blanched vegetables)

FRUIT Blast Freeze 60 mins up to 240 mins (Berries, rhubarb, apples, - cooked or raw fruit)
DESSERTS Blast Freeze 70 mins up to 240 mins (Raw pastry, mousses, cooked cream desserts, cooked
pastry desserts, gateaux)
VACUUM PACKED SOUPS/SAUCES Blast Freeze 90 mins up to 240 mins (All types of sauces)
(max 4kg)
BAKERY PRODUCTS
Dough/Bread Blast Freeze 70 mins up to 240mins
Cakes Blast Freeze 70 mins up to 240mins

Cream Cakes/Gateaux Blast Freeze 50 mins up to 240mins


Pastry Blast Freeze 50 mins up to 240mins
www.williams-refrigeration.co.uk

COOK FREEZE NUTRITIONAL


A Cook-Freeze system involves the Following full cooking, if required, the
INFORMATION
full cooking of food, followed by rapid product should be portioned ready for
freezing and storage of food at Blast Freezing ready for storage in a Cooking food always results in the
-18º/-22ºC, before controlled and frozen food cabinet for several weeks loss of some nutrients, and there
thorough thawing and regeneration or months at below -18ºC. The Blast can be a further steady loss while
prior to service. Freeze cycle transforms the liquid the food is kept chilled. However, if
present in the food into microcrystals the Department of Health Guidelines
Blast Freezing can also be used for
which do not damage the tissue on Cook-Chill and Cook-Freeze
raw materials and semi manufactured
structure of the product and ensures procedures are followed closely, the
products.
the quality of the food is maintained loss of nutrients from food should be
The Guidelines on Cook-Chill and so you still have a high quality product no greater than those from any other
Cook-Freeze Catering Systems (DHS) after defrosting. conventional catering system.
require that the food core temperature
NB: Frozen food storage cabinets are Nutrition and flavour effects are
is reduced from +90ºC to -18ºC within
often loosely referred to as ‘Freezers’, explained in more detail in the
240 minutes (4 hours - see graph on
however, their purpose is specifically Department of Health Guidelines.
page 15). A range of Williamsn Reach-
to store pre-frozen foods, not to
in models offer the dual function of
freeze hot foods. Williams offers a
Blast Chilling and Blast Freezing,
comprehensive range of Freezer and
whilst there are a range of dedicated
Overnight Thaw cabinets for safe
Modular Roll-in Blast Freezers for
storage and controlled thawing of
larger volumes. As well as a Blast
products after Blast Freezing.
Freezer, suitable storage cabinets for
frozen food and preferably a controlled
thawing cabinet are required.
www.williams-refrigeration.co.uk

EQUIPMENT.
For the same reason, the Blast
Equipment for rapid chilling Features to look for: Chiller must be sited near enough to
There are two common methods of Whatever the type of Blast Chiller or
thecooking area to allow for this time
rapid chilling: Chiller Freezer you choose, it must be
limit to be met.
capable of reducing the temperature
1. Using an electro mechanical
of a 50mm layer of food from +90°C Make sure that the model you choose
Blast Chiller, which circulates low
to between 0°C and +3°C within 90 is compatible with the electrical supply
temperature air at high velocity.
minutes, when fully loaded. you have. Smaller models will operate
2. The immersion of packed products satisfactorily on a 240 volt domestic
It must also feature an accurate (+/-
in a suitable refrigerated liquid. supply.
0.5°C) temperature display, with a built-
The first of these options is the most in food probe featuring digital display. The best equipment is made from
suitable and convenient for caterers. Digital and audible timers are also stainless steel. You should also look
useful features. for a good seal around the door. Poor
There are two common types:-
seals mean an inefficient machine
Upon completion of the rapid
and will cost you money in increased
Large Modular Roll-in chill cycle, the machine should
power consumption and less effective
Models automatically revert to storage mode
to comply with the important times
(0°C/+3°C), until the chilling mode
These are suitable for high volume referred to in the Cook-Chill/Freeze
is selected again. This enables the
operations such as hospitals, airline Guidelines.
operator to put one load in last thing
kitchens, schools and correctional
at night, for example, and remove Pay close attention to the design.
facilities. These are designed to move
the chilled product first thing in the It should be possible to have easy
one or more racks of food at a time.
morning. access to the evaporator compartment
for cleaning and servicing.
Reach-In Models Where needed, Williams offers the
These process much smaller amounts facility to audit temperatures at the Look for removable shelf sides and
and are more suited to restaurants, end of the process via a printer or data racking. Cabinets with these features
pubs, function caterers, etc, or where port. are easier to clean.
space is limited.
When selecting a Blast Chiller or Chiller Automatic defrost and evaporation
Some models can Blast Chill and/ Freezer, be sure that its capacity are essential features to look for when
or Blast Freeze should you wish to is sufficient to match maximum selecting a machine.
operate both systems. production so that rapid chilling can
commence within 30 minutes after
cooking.
www.williams-refrigeration.co.uk

THE WILLIAMS PRODUCT RANGE


Take control of the Cook-Chill process
and eliminate the hazards of slow
WBC10/WBCF10 WBC40/WBCF40
• Capacity 10kg • Capacity 40kg
cooling with this range of stylish,
powerful Reach-in Blast Chillers and • Blast Chiller or Dual Function - Chill • Blast Chiller or Dual Function - Chill
Chiller Freezers. Designed for small and Freeze and Freeze
and medium sized catering operations
• Accommodates 3 1/1Gastronorm • Accommodates 10 1/1Gastronorm
the Williams range combine style, ease
pans pans
of use and state of the art technology.
• Dimensions: H885 x D804 x • Dimensions: H1735 x D804 x
• Designed to accommodate 1/1
W707mm W707mm
Gastronorm containers
• Stainless steel exterior and interior WBC20/WBCF20 WBC50/WBCF50
• Capacity 20kg • Designed for larger catering
• Hard and Soft Chill Options
operations
• Blast Chiller or Dual Function - Chill
• Designed for 43ºC ambient
and Freeze • Suited to 43ºC ambient
environments
environments
• Accommodates 6 1/1Gastronorm
• Easy to use as 1-2-3 with the simple
pans • Accommodates 13 1/1 Gastronorm
control panel or using the single
pans
core food temperature probe • Dimensions: H1290 x D804 x
W707mm • Uses simple 1-2-3 control panel and
• Designed to Blast Chill the full
single core food temperature probe
capacity from +90ºC/+3ºC in 90
minutes and dual function models
WBC30/WBCF30 • Capacity 50kg
Blast Freeze a full load from • Capacity 30kg
• Blast Chiller of Dual Function - Chill
+90ºC/-18ºC in 240 minutes*
• Blast Chiller or Dual Function - Chill and Freeze
and Freeze
• WBC50/WBCF50 are 3 phase and
• Accommodates 10 1/1Gastronorm require connection to a main drain
pans
• Dimensions: H1905 x D804 x
• Dimensions: H1735 x D804 x W707mm
W707mm

*Blast Chill full load at 40mm depth / Blast Freeze full load at 20mm depth
All Williams models feature CFC free insulation and 12 month warranty. We reserve the right to change the specification without notice.
www.williams-refrigeration.co.uk

Jade J1BC
• Blast Chiller only
• Blast Chills 23kg from +70°C to
+3°C in 90 mins
• Accommodates various sized
containers on 7 shelves or racked
out for 1/1 GN containers
• Simple to operate using 1-2-3
controls or core food temperature
probe
• Features Hard and Soft Chill options
• Reverts to storage mode at the end
of Blast Chill cycle
• Designed for 43°C ambient
environments
• Dimensions: H1982 x D792 x
W865mm

WILLIAMS RANGE OF REACH IN BLAST CHILLERS


www.williams-refrigeration.co.uk

A SELECTION FROM THE WILLIAMS PRODUCT


RANGE
Designed for larger foodservice
operations such as corporate catering,
WMBC120 WMBC320
• Capacity 320kg
large hotels, hospitals or airline • Capacity 120kg
• Blast Chiller with Blast Freeze option
catering, the Williams range of Modular • Blast Chiller with Blast Freeze option
available
Blast Chillers, Blast Chiller Freezers available
• Accommodates 2 2/1 GN or Combi
and Blast Freezers are installed all over • Accommodates 1 2/1 GN or Combi
oven trolleys
the world. oven trolley
• Dimensions: H2295 x W1370 or
• Dimensions: H2295 x W1370 or
Featuring Williams unique easy to 1570 x D2350mm
1570 x D1250mm
operate 1-2-3 control panel offering the • Choice of door opening of 700mm
• Choice of door opening of 700mm
choice of timed cycles or control using or 900mm
or 900mm
three core food temperature probes,
the modular range are designed to
WMBC160 WMBF100
accommodate standard Gastronorm • Capacity 100kg
• Capacity 160kg
or Combi oven trolleys. • Blast Chiller with Blast Freeze option
• Blast Chiller with Blast Freeze option
available
Stainless steel interior and exterior available
• High performance rapid Blast
as standard, a choice of finishes is • Accommodates 1 2/1 GN or Combi
Freezing of 100kg from +90/-18ºC
available to suit all budgets. With easy oven trolley
in 90 minutes
to access large area evaporators and • Dimensions: H2295 x W1370 or
• Accommodates 1 2/1 GN or Combi
high velocity fans for even chilling and 1570 x D1250mm
oven trolley
efficient operation, easy cleaning and • Choice of door opening of 700mm
• Dimensions: H2295 x W1370 or
servicing, the modular roll-in range or 900mm
1570 x D1250mm
offer the option of roll-through design
• Choice of door opening of 700mm
and Williams unique “pod” refrigeration WMBC200 or 900mm
system for longer term storage. Blast • Capacity 200kg
• 90mm insulated floor either
Freezing is an optional upgrade on • Blast Chiller with Blast Freeze option
recessed or with ramp
Blast Chiller Models available
• Accommodates 1 2/1 GN or Combi
WMBC90 oven trolley
WMBF200
• Capacity 200kg
• Capacity 90kg • Dimensions: H2295 x W1370 or
• Blast Chiller with Blast Freeze option
• Blast Chiller with Blast Freeze option 1570 x D1250mm
available
available • Choice of door opening of 700mm
• High performance rapid Blast
• Accommodates 1 2/1 GN or Combi or 900mm
Freezing of 200kg from +90/-18ºC
oven trolley
in 90 minutes
• Dimensions: H2295 x W1370 or WMBC240 • Accommodates 2 2/1 GN or Combi
1570 x D1250mm • Capacity 240kg
oven trolleys
• Choice of door opening of 700mm • Blast Chiller with Blast Freeze option
• Dimensions: H2295 x W1370 or
or 900mm available
1570 x D2350mm
• Accommodates 2 2/1 GN or Combi
• Choice of door opening of 700mm
oven trolleys
or 900mm
• Dimensions: H2295 x W1370 or
• 90mm insulated floor either
1570 x D2350mm
recessed or with ramp
• Choice of door opening of 700mm
or 900mm
www.williams-refrigeration.co.uk

WILLIAMS ROLL-IN BLAST CHILLERS


www.williams-refrigeration.co.uk

Greenlogic is Williams’ commitment our global facilities, for the design,


to supplying the most energy manufacture, installation and servicing
efficient and sustainable commercial of refrigeration products.
refrigeration in the market today.
Every manufacturing process is
All Williams products must meet continually monitored by trained staff
our strict environmental criteria. to ensure we maximise re-use and
Every component is considered and recycling, and minimise waste.
evaluated for the contribution they
Our Greenlogic Customer Support
make to the product’s overall energy
helps you make the right decisions for
efficiency as well as the impact they
your business and the environment.
have on the environment. We ensure
As well as helping to identify the
components have been sourced or
most energy efficient and sustainable
produced in a sustainable and ethical
products, Greenlogic Customer
manner. All Williams components are
Support offers practical advice on how
manufactured to our rigorous quality
to save energy, time, resources and
standards ensuring the product
money, while creating a better working
delivers the longest possible service
environment.
life.
Greenlogic forms an important
Greenlogic is not limited to product
part of Williams Corporate Social
design: it covers our manufacturing
Responsibility – and can be part of
and management processes too.
yours too.
Williams holds the environment
certification ISO 14001 throughout
www.williams-refrigeration.co.uk

GLOSSARY
Blast Chiller rapidly. slowest cooling point - normally the
centre.
A mechanical unit designed to chill Blast Freezer
hot food rapidly - from +70ºC to +3ºC Pathogenic Micro-Organisms
A mechanical unit designed to freeze
within 90 mins. It works by recirculating
hot food rapidly - from +70ºC to -18ºC All foods contain a certain level of
low temperature air at high velocity.
within 240 mins (4 hours). organisms or bacteria which can carry
Hard Blast Chill - +90ºC to +3ºC in disease if allowed to multiply to large
Blast Freeze - +70ºC to -18ºC in
90 mins numbers. Cooking food kills them,
240 mins
while keeping food below certain
Blast Chill cycle suitable for denser
Fast freezing of cooked foods to temperatures limits their growth.
items with a higher fat content such
-18ºC which transforms the liquid
as meat joints, meat based sauces, Consequently, a Cook-Chill system is
present in the food into microcrystals –
soups, sponge cakes, mashed potato a good way of maintaining food safety
preventing damage to tissue structure
and vacuum packed products. The as it controls bacteria growth.
of the product and ensures food
air temperature of the cabinet drops
quality after defrosting. During the Probe
below freezing point during the 90
cycle the air temperature of the cabinet
minute cycle. A thermometer that is inserted into
reaches -25ºC or -35ºC (dependent on
a food product to record the inner
Soft Blast Chill - +90ºC to +3ºC in model used - see graph on page 15).
temperature. The needle probe should
90 mins
Chill Chain be disinfected each time using a
Blast Chill cycle suitable for delicate special impregnated tissue or cloth.
The whole process of maintaining strict
and light products such as fish, rice,
temperature control throughout receipt, Regeneration
vegetables, cream, desserts and fried
storage, preparation, processing,
foods. During the 90 minute cycle the The technical term for returning the
storage and distribution of food to
air temperature of the cabinet remains pre-cooked chilled food back to the
control the growth of micro-organisms.
above 0ºC. safe temperature of +90ºC ready for
Food Core immediate serving.
Blast Chiller Freezer
The temperature within an item of
A mechanical dual function unit
food or dish. Temperature taken at the
designed to chill or freeze hot food
www.williams-refrigeration.co.uk

SUMMARY

RAW MATERIALS BLAST CHILL CHILLED STORAGE


• Buy from reputable suppliers. • The rapid chilling process • Cook/Chill foods should be
must begin within 30 minutes stored in a cabinet designed
• Choose good quality
of cooking being completed. for the purpose.
products.
• Once in the chiller, the • Pre-cooked chilled food
food must be chilled to a should be stored at between
temperature between 0°C and 0°C and +3°C for a maximum
+3°C within 90 minutes. period of 5 days.
• Foods such as joints of meat • If the storage temperature
STORAGE can be chilled to below +10°C rises to over +5°C, but no
• Raw materials should be within 150 minutes before more than +10°C, the food
stored at recommended portioning and final chilling. should be consumed within
temperature and humidity 12 hours.
levels, in accordance with the
• Food should be clearly
Food Safety (Temperature
labelled with a description,
Control) Regulations 1996.
production date and expiry
date.
• A stock rotation system
should be operated.
PREPARATION
• Raw materials should be
prepared in areas separated
from cooking and post-
cooking areas.
• Products should be held at
temperatures below +10°C
until cooking commences.
• Frozen products should be
control thawed before use.
FROZEN STORAGE
• Pre-cooked frozen food
should be stored at -18°C or
below.
COOKING • Foods should be clearly
• The core temperature of food BLAST FREEZE marked with a description,
must reach at least +70°C • The rapid freezing process
production date and expiry
and should be held at this must begin within 30 minutes
date.
temperature for at least two of cooking being completed.
minutes. • A stock rotation system
• Once in the freezer, the
should be operated.
• Check the core temperature food must reach a core
using a probe thermometer temperature of at least -5°C • Generally, frozen foods may
inserted into the slowest within 90 minutes, and a be stored for up to eight
heating point, normally the subsequent temperature of at weeks, although certain foods
centre. least -18°C. can be stored for longer.
www.williams-refrigeration.co.uk

DISTRIBUTION RETHERMALIZATION SERVICE


• Pre-cooked chilled foods • Cooked and chilled foods • Once food has been
must remain in their chilled that are to be eaten cold regenerated to the required
state (0°C to +3°C), until they should be consumed within temperature, it should be
reach the regeneration site. 30 minutes after removal from consumed as soon as
storage. possible, and preferably within
• If the core temperature rises
15 minutes of reheating.
to over +5°C, but no more • Regeneration must take
than +10°C, the food must be place close to the point of • The temperature of the
consumed within 12 hours. consumption. reheated food should not be
allowed to drop below +65°C.
• If the core temperature rises • The core temperature of the
above +10ºC the food must food must reach at least • Any food left after service
be discarded. +70°C and be held at this which has been regenerated
temperature for at least two must be destroyed.
minutes.
• Regenerated food that has
cooled below +65ºC should
be reheated for service.

REGENERATION
• Regeneration must take
place close to the point of
consumption.
DISTRIBUTION THAW • The core temperature of the
• Frozen foods must
• Pre-cooked frozen foods food must reach at least
be transported to the
must be fully thawed before +70°C and be held at this
regeneration site under
regeneration. temperature for at least two
controlled conditions.
minutes.
• Thawing must be controlled,
• If a product starts to thaw, it
preferably with the use of a • Reheated food that has
must not be refrozen.
controlled thawing cabinet. cooled should be reheated
above +65ºC.
• Food thawed rapidly in fast
thaw cabinets should be • Reheated food should not be
consumed within 24 hours. re-frozen.
• Thawed foods must not be • Regenerated food not sold
re-frozen. must be destroyed.
www.williams-refrigeration.co.uk

Design Excellence : Cool Technology

www.williams-refrigeration.co.uk

UK Office Hong Kong Office Australia Office Dubai Office


Bryggen Road 4A, Harrington Building, 38-42 Gaine Road, 18th Floor Crown Plaza
North Lynn Industrial Estate 36-50 Wang Wo Tsai Street, Dandenong South, Commercial Tower, Sheikh
Kings Lynn Tsuen Wan, Victoria 3175, Zayed Road. Dubai, United Arab
Norfolk PE30 2HZ Hong Kong Australia Emirates
T +44 (0) 1553 817 000 T (852) 2407 5422 T (61) 3 8787 4747 T +971 4 311 7145
F +44 (0) 1553 817 111 F (852) 2407 3767 F (61) 3 8787 4787 F +971 4 332 8860
E info@williams-refrigeration.co.uk E sales@williams-hongkong.com E sales@williamsref.com.au E sales@williamsdubai.ae

Williams Refrigeration is a trading name of AFE Group Limited.


Registered in England & Wales under Registered Number 3872673.
Registered Office Address - Bryggen Road, North Lynn, Industrial Estate, Kings Lynn, Norfolk, PE30 2HZ MK/Lit/CCG-GB-01/V1

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