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Premium member Presentation Transcript Cook-Chill Food Safety Principles: Cook-Chill Food Safety Principles Retail Meat & Poultry Processing Training ModulesProduced under a Cooperative Agreement from the United States Department of Agriculture Food Safety and Inspection Service (FSIS): Produced under a Cooperative Agreement from the United States Department of Agriculture Food Safety and Inspection Service (FSIS) Developed by: Minnesota Department of Agriculture, Dairy and Food Inspection Division Hennepin County Environmental Health Minnesota Department of Health University of Minnesota Extension Service September 2004Pretest : PretestTopics: Topics The cook-chill concept Importance of rapid cooling over the proper time frame Importance of monitoring temperatures Methods of quick chill and cooling Importance of product formulation Types of cook-chill products Two basic types of packaging Labeling of products Importance and significance of having a HACCP plan and a recordkeeping system Potential problems associated with cook-chill productsLearning Objectives: Learning Objectives Describe the concept of cook-chill. Recite the correct temperature range and time frame for rapid cooling. Monitor and record temperatures during the cook-chill process accurately. Properly package and label cook-chill products. Identify the critical control points of a HACCP plan with cook-chill processing. List 2 potential problems associated with cook-chill products.The Cook-Chill Concept: The Cook-Chill Concept Cook-chill is a process of batch food production . It enables a fresh product to be cooked, packaged and rapidly cooled . Cook Bag ChillCook-Chill . . .: Cook- Chill . . . . . . is a food processing method that uses the HEAT of pasteurization temperature (depending on time ) to: Destroy disease-causing organisms Reduce spoilage microorganisms Inactivate (Stop) natural “enzymes”Cook-Chill . . .: Cook -Chill . . . . . . and then use the COLD temperature (28 °F - 32°F) to quickly chill the product in order to maintain the product at < 41°F to: Slow growth of spoilage microorganisms Prevent the production of toxins in certain microorganismsTemperature Danger Zone: Temperature Danger ZoneCritical Control Temperatures in Process: Critical Control Temperatures in Process Ingredient Handling Temperature of food when received Holding temperatureCritical Control Temperatures in Process: Critical Control Temperatures in Process Cooking Proper temperature per Food CodeCritical Control Temperatures in Process: Critical Control Temperatures in Process Cooling 140 ° F to 70 ° F in two hours 70 ° F to 41 ° F in four more hours Muscle Meats are 120 ° F to 55 ° F in 6 hoursCooling Factors: Cooling Factors Cooling factors include: bag fill how thick the product is; and density of the product.METHODS OF CHILLING: METHODS OF CHILLING Blast Chilling utilizes high velocity cold air Water Bath Chilling manual rotation of product in an ice bath which contains a high ratio of ice to water Mechanical Tumble Chilling sealed in air tight bags and immersed in cold water in an automated tumbling drumCritical Control Temperatures in Process: Critical Control Temperatures in Process Cold storage of cooked products less than 41 ° FExterior & Interior of Tumble Chiller: Exterior & Interior of Tumble ChillerPowerPoint Presentation: Chilling Key : Properly sized equipment Chill rapidly for quality and safety For chilled tray line – everything must be in a chilled state Remember: Some foods cooked and chilled Some foods seasoned and held chilledPowerPoint Presentation: Water Bath Chilling Need to have enough water to accept the heat given off by the product. Must be able to fold and massage heavy product for rapid chilling. To package properly, remove air and make a long “neck” so the food has room to move around and there is greater surface area. Must have adequate ice water supply.PowerPoint Presentation: When To Choose Blast Chilling Items that don’t take any longer to cook than they do to reheat, or items that cannot be pumped like grilled, fried, steamed foods. Your business serves fewer than 1,500 meals/day but you want the advantage of chilled meal assembly. You have one (1) rack/every 25 gallon of product that you need to chill.Blast Chilling Process: Blast Chilling Process Prepare food Chill in blast chiller in 1 to 2 hours Cover lightly Use within 7 daysCritical Control Temperatures Reheating and Holding: Critical Control Temperatures Reheating and Holding Reheating - must bring the product up to 165 ° F for 15 seconds to reduce microbial growth Hot holding - 140 ° F or hotter Cold storage of cooked products less than 41 ° F Frozen storage - 0 ° F or lowerProduct Formulation: Product Formulation Standard recipes need to be adapted to the cook-chill process.TYPES OF COOK-CHILL PRODUCTS: TYPES OF COOK-CHILL PRODUCTS Cold Packed: Mix cold ingredients. Put in an air tight bag. Vacuum is pulled. Bag is clipped or sealed. Examples: Dressings Jell-O Salads Pasta Salads Vegetable Salads (potato, slaws etc.)TYPES OF COOK-CHILL PRODUCTS: TYPES OF COOK-CHILL PRODUCTS Hot Packed: Cook product to proper temperature. Heat product to pasteurization temperatures based on time. Package in an air tight bag. Rapidly chill to 41 º F or less in one hour or less. Examples: Gravy Soups Sauces Rice Pasta Vegetables--potatoes, carrots. . . Cereals Entrée’s—casseroles Whole muscle meat--beef, chicken, pork.Two Basic Packaging Aspects for Chilled Foods: Two Basic Packaging Aspects for Chilled Foods Package-Cook ( Sous vide pronounced soo veed ) Cook-PackagePackage-Cook (Sous vide): Package-Cook ( Sous vide ) Food is packaged Heated (Pasteurized) in cook tank Chilled in cook tank by chilled water Stored at less than 35 ° F Method is less expensive and has a higher degree of safety because of little risk of post-pasteurization contamination Examples: Cryovac packages of roast beef & turkey, rice and fish filetsCook-Package: Cook-Package Heated (pasteurized) in kettle Chilled within 4 hours usually ice bath or tumble chiller Packaged in oxygen proof casing Stored under refrigeration Higher risk of post-pasteurization contamination Examples: soups, gravies, stewsLabeling of Product: Labeling of Product What to include on the label: Re-heating instructions Date made Product name Lot number Place of manufacture Storage information Ingredients Number of servings Net weight/volumeAn Example of a Labeled Crimped Bag: An Example of a Labeled Crimped BagWritten HACCP Plan: Written HACCP Plan HACCP is a good foundation for a written plan: Formulation of foods (recipes) Sanitation Operating ProceduresRECORD KEEPING: RECORD KEEPING Thermometer calibration Record retentionPossible Problems: Possible Problems Poor recipes not correctly adapted to cook-chill Improper reheating of food Inadequate training of personnel Poor inventory control of banked foodPossible Problems: Possible Problems Not all menu items are compatible with cook-chill including: Fried foods Pancakes and French toast Sandwiches and deli meats Hot vegetables and vegetable salads Baked potato, roasted and new potatoesWho Does Cook-Chill Work For?: Who Does Cook-Chill Work For? Those serving more than 600 – 800 meals per day Those who have more than one serving location Those who have food temperature problems because of distance they have to transport or the time that it may take to get it thereWho Does Cook-Chill Work For?: Who Does Cook-Chill Work For? Those who want to control the consistency and the quality of their product from serving location to serving location Those with limited production space and a large number of meals to produceWho does Cook-Chill work for?: Who does Cook-Chill work for? Those whose needs are expanding rapidly Those who have a great deal of competition for labor, particularly skilled cooksSummary: Summary Cook-chill is a process that uses both HEAT and COLD for batch food production. Temperature monitoring and recording is critical in production of cook-chill products to avoid foodborne illness. Not all food products can be cook-chill processed. Proper packaging and labeling of cook-chill products is needed for shelf life and recall purposes. Cook-chill products must be reheated to 165 ° F for safety.Wrap-Up: Wrap-Up Do you have any questions? What information was new? How will you apply what you learned today? Posttest You do not have the permission to view this presentation. In order to view it, please contact the author of the presentation.
presentation cook chill badrulhisham Download Post to : URL : Related Presentations : Share Add to Flag Embed Email Send to Blogs and Networks Add to Channel Uploaded from authorPOINT lite Insert YouTube videos in PowerPont slides with aS Desktop Copy embed code: Embed: Flash iPad Copy Does not support media & animations WordPress Embed Customize Embed URL: Copy Thumbnail: Copy The presentation is successfully added In Your Favorites. Views: 195 Category: Entertainment License: All Rights Reserved Like it (0) Dislike it (0) Added: January 20, 2012 This Presentation is Public Favorites: 0 Presentation Description No description available. Comments Posting comment... Premium member Presentation Transcript Cook-Chill Food Safety Principles: Cook-Chill Food Safety Principles Retail Meat & Poultry Processing Training ModulesProduced under a Cooperative Agreement from the United States Department of Agriculture Food Safety and Inspection Service (FSIS): Produced under a Cooperative Agreement from the United States Department of Agriculture Food Safety and Inspection Service (FSIS) Developed by: Minnesota Department of Agriculture, Dairy and Food Inspection Division Hennepin County Environmental Health Minnesota Department of Health University of Minnesota Extension Service September 2004Pretest : PretestTopics: Topics The cook-chill concept Importance of rapid cooling over the proper time frame Importance of monitoring temperatures Methods of quick chill and cooling Importance of product formulation Types of cook-chill products Two basic types of packaging Labeling of products Importance and significance of having a HACCP plan and a recordkeeping system Potential problems associated with cook-chill productsLearning Objectives: Learning Objectives Describe the concept of cook-chill. Recite the correct temperature range and time frame for rapid cooling. Monitor and record temperatures during the cook-chill process accurately. Properly package and label cook-chill products. Identify the critical control points of a HACCP plan with cook-chill processing. List 2 potential problems associated with cook-chill products.The Cook-Chill Concept: The Cook-Chill Concept Cook-chill is a process of batch food production . It enables a fresh product to be cooked, packaged and rapidly cooled . Cook Bag ChillCook-Chill . . .: Cook- Chill . . . . . . is a food processing method that uses the HEAT of pasteurization temperature (depending on time ) to: Destroy disease-causing organisms Reduce spoilage microorganisms Inactivate (Stop) natural “enzymes”Cook-Chill . . .: Cook -Chill . . . . . . and then use the COLD temperature (28 °F - 32°F) to quickly chill the product in order to maintain the product at < 41°F to: Slow growth of spoilage microorganisms Prevent the production of toxins in certain microorganismsTemperature Danger Zone: Temperature Danger ZoneCritical Control Temperatures in Process: Critical Control Temperatures in Process Ingredient Handling Temperature of food when received Holding temperatureCritical Control Temperatures in Process: Critical Control Temperatures in Process Cooking Proper temperature per Food CodeCritical Control Temperatures in Process: Critical Control Temperatures in Process Cooling 140 ° F to 70 ° F in two hours 70 ° F to 41 ° F in four more hours Muscle Meats are 120 ° F to 55 ° F in 6 hoursCooling Factors: Cooling Factors Cooling factors include: bag fill how thick the product is; and density of the product.METHODS OF CHILLING: METHODS OF CHILLING Blast Chilling utilizes high velocity cold air Water Bath Chilling manual rotation of product in an ice bath which contains a high ratio of ice to water Mechanical Tumble Chilling sealed in air tight bags and immersed in cold water in an automated tumbling drumCritical Control Temperatures in Process: Critical Control Temperatures in Process Cold storage of cooked products less than 41 ° FExterior & Interior of Tumble Chiller: Exterior & Interior of Tumble ChillerPowerPoint Presentation: Chilling Key : Properly sized equipment Chill rapidly for quality and safety For chilled tray line – everything must be in a chilled state Remember: Some foods cooked and chilled Some foods seasoned and held chilledPowerPoint Presentation: Water Bath Chilling Need to have enough water to accept the heat given off by the product. Must be able to fold and massage heavy product for rapid chilling. To package properly, remove air and make a long “neck” so the food has room to move around and there is greater surface area. Must have adequate ice water supply.PowerPoint Presentation: When To Choose Blast Chilling Items that don’t take any longer to cook than they do to reheat, or items that cannot be pumped like grilled, fried, steamed foods. Your business serves fewer than 1,500 meals/day but you want the advantage of chilled meal assembly. You have one (1) rack/every 25 gallon of product that you need to chill.Blast Chilling Process: Blast Chilling Process Prepare food Chill in blast chiller in 1 to 2 hours Cover lightly Use within 7 daysCritical Control Temperatures Reheating and Holding: Critical Control Temperatures Reheating and Holding Reheating - must bring the product up to 165 ° F for 15 seconds to reduce microbial growth Hot holding - 140 ° F or hotter Cold storage of cooked products less than 41 ° F Frozen storage - 0 ° F or lowerProduct Formulation: Product Formulation Standard recipes need to be adapted to the cook-chill process.TYPES OF COOK-CHILL PRODUCTS: TYPES OF COOK-CHILL PRODUCTS Cold Packed: Mix cold ingredients. Put in an air tight bag. Vacuum is pulled. Bag is clipped or sealed. Examples: Dressings Jell-O Salads Pasta Salads Vegetable Salads (potato, slaws etc.)TYPES OF COOK-CHILL PRODUCTS: TYPES OF COOK-CHILL PRODUCTS Hot Packed: Cook product to proper temperature. Heat product to pasteurization temperatures based on time. Package in an air tight bag. Rapidly chill to 41 º F or less in one hour or less. Examples: Gravy Soups Sauces Rice Pasta Vegetables--potatoes, carrots. . . Cereals Entrée’s—casseroles Whole muscle meat--beef, chicken, pork.Two Basic Packaging Aspects for Chilled Foods: Two Basic Packaging Aspects for Chilled Foods Package-Cook ( Sous vide pronounced soo veed ) Cook-PackagePackage-Cook (Sous vide): Package-Cook ( Sous vide ) Food is packaged Heated (Pasteurized) in cook tank Chilled in cook tank by chilled water Stored at less than 35 ° F Method is less expensive and has a higher degree of safety because of little risk of post-pasteurization contamination Examples: Cryovac packages of roast beef & turkey, rice and fish filetsCook-Package: Cook-Package Heated (pasteurized) in kettle Chilled within 4 hours usually ice bath or tumble chiller Packaged in oxygen proof casing Stored under refrigeration Higher risk of post-pasteurization contamination Examples: soups, gravies, stewsLabeling of Product: Labeling of Product What to include on the label: Re-heating instructions Date made Product name Lot number Place of manufacture Storage information Ingredients Number of servings Net weight/volumeAn Example of a Labeled Crimped Bag: An Example of a Labeled Crimped BagWritten HACCP Plan: Written HACCP Plan HACCP is a good foundation for a written plan: Formulation of foods (recipes) Sanitation Operating ProceduresRECORD KEEPING: RECORD KEEPING Thermometer calibration Record retentionPossible Problems: Possible Problems Poor recipes not correctly adapted to cook-chill Improper reheating of food Inadequate training of personnel Poor inventory control of banked foodPossible Problems: Possible Problems Not all menu items are compatible with cook-chill including: Fried foods Pancakes and French toast Sandwiches and deli meats Hot vegetables and vegetable salads Baked potato, roasted and new potatoesWho Does Cook-Chill Work For?: Who Does Cook-Chill Work For? Those serving more than 600 – 800 meals per day Those who have more than one serving location Those who have food temperature problems because of distance they have to transport or the time that it may take to get it thereWho Does Cook-Chill Work For?: Who Does Cook-Chill Work For? Those who want to control the consistency and the quality of their product from serving location to serving location Those with limited production space and a large number of meals to produceWho does Cook-Chill work for?: Who does Cook-Chill work for? Those whose needs are expanding rapidly Those who have a great deal of competition for labor, particularly skilled cooksSummary: Summary Cook-chill is a process that uses both HEAT and COLD for batch food production. Temperature monitoring and recording is critical in production of cook-chill products to avoid foodborne illness. Not all food products can be cook-chill processed. Proper packaging and labeling of cook-chill products is needed for shelf life and recall purposes. Cook-chill products must be reheated to 165 ° F for safety.Wrap-Up: Wrap-Up Do you have any questions? What information was new? How will you apply what you learned today? Posttest