Kuusamo Food Service kitchen changed to a more effective operation model when the new modern central kitchen Salvi replaced four old regional kitchens. In the process the previous Cook-Hold operation model was replaced with a more cost-effective Cook-Chill model. One new equipment category was five new pans which of three were cook-mix-chill operated mixer kettles. Implementing the cook-chill helped bring more flexibility and save a significant amount of time and resources.
A change to more effective operation with Cook-Mix-Chill applications
Kuusamo Food Service kitchen serves day care centers, schools, health care centers, home service customers, personnel restaurants and catering services. The kitchen had the highest cost per sqm in the building, and therefore the importance of an optimized lay-out, an effective operation model, and the right equipment to support the operation were crucial to generate considerable cost savings.
To meet this goal a restoration project for the new central kitchen “Salvi” was decided. The new kitchen replaces 4 regional kitchens and approximately 1600 meals are prepared each day for the Kuusamo region in the new and modern central kitchen.
“Implementing a new Cook-Chill operation model in parallel to the current Cook-Hold model and concentrating food preparation to one central kitchen is a must for the meal service functions in order to be able to efficiently meet future needs” explains kitchen manager Marja Pitkänen.
“The implementation of Cook-Chill increases flexibility. When all food preparation, ingredient procurement, and logistics are centralized, personnel time and resources are saved."
All equipment categories were bidden, and decisions were based on quality requirements established in the procurement process. One equipment category was 5 new kettles of which three represented the latest in technology connected to an ice bank consisting of 4400 L ice water and 1800 kg ice. The high-speed chilling kettles allows a part of the food processing to use a Cook-Chill operational model. The chilled food is then distributed to satellite kitchens where the food is reheated either in combi ovens or in heating carriers. On the side of Cook-Chill, Cook-Hold operations can also continue as before.
Cost-effective cook-chill method
Previously food was prepared in 4 regional kitchens, all distributed hot. Transports were daily, usually between 9 o’clock and noon. The implementation of Cook-Chill increases flexibility. Food preparation is now possible throughout the working day, which also increases equipment utilization. When all food preparation, ingredient procurement, and logistics are centralized, personnel time and resources are saved.
"When the recipes are optimized, food quality will be consistent and we save time as the kettle handles everything independently, from preparation to chilling”
-kitchen manager Marja Pitkänen
Cook-Chill method saves transport costs as meals are now distributed only three times a week and transport takes place during the afternoon. Cook-Chill operations are not dependent on tight preparation- and transport- schedules in the same way as Cook-Hold.
Optimizing recipes for cook-chill operation
“It is important to remember that all foods are not suitable for kettle chilling and the only way to establish that is through testing. The kettles equipped with the modern control panel give the opportunity to program your own recipes and therefore we started to perform Cook-Chill tests already months before. In the beginning changes are done continuously. Later when the recipes are optimized, food quality will be consistent and we save time as the kettle handles everything independently, from preparation to chilling”
Dieta kettles for Central production kitchens
Maintain high quality
Maintain high capacity requirements
Uphold safety requirements
Increased productivity with automatic cooking