A COMPREHENSIVE WHITE PAPER: COOK QUENCH CHILL ‘ADAPT’

April 17, 2024

Author: Emma Hodgson, Marketing Executive

In the dynamic world of food processing, efficiency and innovation are not just goals; they are necessities. DC Norris, a leader in the industry, has consistently set benchmarks in this domain.
The introduction of the Cook Quench Chill ‘Adapt’ system marks a significant milestone, offering a solution that is not only technologically advanced but also environmentally conscious.
This white paper delves into the intricacies of this ground-breaking system, exploring its innovative features, technical specifications, and the profound impact it has on the food processing industry.

Innovation in Cook Quench Chill Technology

The Cook Quench Chill ‘Adapt’ system by DC Norris represents a leap forward in food processing technology. Stemming from a need for more energy-efficient and versatile
solutions, this system represents DC Norris’s commitment to innovation. Its modular design and optimum performance cater to a wide range of food processing needs, from
pasta and rice to vegetables and proteins.

Patented Jet Cook™ Technology: A Game-Changer

At the heart of the ‘Adapt’ system lies the patented Jet Cook™ technology. This direct steam heat system revolutionises the cooking process by significantly accelerating heating and cooking times. For instance, it can heat 575kg of water from 20°C to 90°C in just 8 minutes, a feat that underlines its efficiency.

This rapid heating capability not only saves time but also reduces energy consumption by up to 50%, a key factor in today’s energy-conscious market.

Maximising Efficiency: Energy and Water Savings

The ‘Adapt’ system’s design focuses on maximising efficiency in every detail. It achieves remarkable water savings through smaller tank sizes, variable water levels, and an innovative starch removal system. These features allow for the reuse of water, further reducing the system’s environmental footprint.
The energy-saving aspect is equally impressive, with the system designed to deliver optimum performance while using the minimum amount of energy. This efficiency translates into a reduced return on investment time, making it an economically attractive option for food processors.

Technical Specifications and Operational Details

Modular Design for Versatile Applications

The Cook Quench Chill ‘Adapt’ systems modular design is a standout feature, offering unparalleled flexibility in food processing. This design allows for easy expansion or reduction in capacity, varying throughput requirements with ease. Such versatility is crucial in an industry where demand and product types can fluctuate significantly. The systems ease of installation further enhances its appeal, reducing both installation times and costs.

Variable Wave Agitation System: Ensuring Quality

Another key component of the ‘Adapt’ system is the Variable Wave Agitation System. This innovative feature ensures high-quality, damage-free processing of delicate food items. By providing a gentle yet effective agitation, it guarantees even cooking and eliminates issues like clumping, which are common in traditional systems. This results in a consistently high-quality product, crucial for maintaining consumer satisfaction and brand reputation.

Real Life Case Studies

Fresh Cut Foods, Nottingham, UK

In 2021, Fresh Cut Foods installed the ‘Adapt’ system to upgrade their manufacturing capability. The system was chosen for its flexibility, increased throughput, and energy efficiency.
Trials at DCN’s Product Development Kitchen led to a system that exceeded expectations in water and energy use, plant and labour productivity, and versatility in cooking mixed batches.
The user-friendly system also provides valuable data logging for product times and temperatures. Chris Copestake, CEO of Fresh Cut Foods, praised the system’s performance and expressed interest in future investments in the ‘Adapt’ technology.

First Cook Quench Chill ‘Adapt’in America

The first American installation of the Cook Quench Chill ‘Adapt’ system exemplifies its practical application and benefits. The system was integrated into a central kitchen, producing a wide range of cooked, chilled ready-prepared meals for supermarket stores. This demonstrates the system’s ability to meet diverse food processing needs while maintaining high standards of quality and efficiency. As well as the new ‘Adapt’, we also installed two Sous Vide Water Tanks and Bratt Pans.

Analysis of Product Cooking & Cooling Trial Data

Demonstrating Efficiency Across Various Products

The trial data provided offers a comprehensive view of the Cook Quench Chill ‘Adapt’ system’s efficiency across a range of products. For instance, the system can cook 50kg of spaghetti in just 9 minutes, with a total process time of 15.5 minutes, resulting in 110 kg of cooked product. This efficiency is mirrored across various types of pasta, rice, and vegetables, showcasing the system’s versatility and capability to handle different food products with ease.

Temperature Control and Productivity Implications

The precise temperature control during the cooking, quenching, and chilling phases is a testament to the system’s advanced design. For example, 65kg (dry) basmati rice is cooked and cooled to the desired temperature within 23 minutes, demonstrating not just speed but also the ability to maintain quality. The data also highlights the system’s high throughput, with significant cooked weight per hour metrics, indicating its potential to enhance production efficiency significantly.

Product Cooking & Cooling Trial Data

Market Impact and Comparative Analysis

Setting New Standards in Food Processing

The Cook Quench Chill ‘Adapt’ system is not just an innovation in technology; it’s a new benchmark in food processing efficiency and sustainability. Compared to traditional systems, it offers significant improvements in energy and water usage, which are critical factors in today’s environmentally conscious market. The system’s reduced carbon footprint and cost-saving capabilities make it a compelling choice for food processors looking to modernise their operations.

Reception and Significance

The market reception of the ‘Adapt’ system, particularly in the American market, underlines its relevance and appeal. The system’s ability to reduce operational costs while maintaining high-quality output aligns with the current industry needs, making it a sought-after solution in the food processing sector.

Future Implications and Developments

Anticipating Technological Evolution

The Cook Quench Chill ‘Adapt’ system, with its current capabilities, sets the stage for future advancements in food processing technology. Its modular design and innovative features provide a foundation for continued enhancements, potentially leading to even more efficient and sustainable food processing methods.

Long-Term Industry Impact

The long-term impact of the ‘Adapt’ system on the food processing industry is expected to be significant. By setting new standards in efficiency and sustainability, it encourages the industry to move towards more environmentally friendly and cost-effective solutions, shaping the future of food processing technology.

Process Management and Data Capture Software

Enhancing Control and Quality Assurance

The integration of process management and data capture software in the Cook Quench Chill ‘Adapt’ system offers an additional layer of control and quality assurance. This software allows for precise recipe control, ensuring consistent product quality and aiding in compliance with food safety standards.

Data-Driven Decision Making

The ability to capture and analyse data enhances the system’s value, enabling food processors to make informed decisions based on accurate process information. This data-driven approach can lead to continuous improvement in food processing operations, optimising both efficiency and product quality.

Conclusion

Revolutionising Food Processing with Innovation and Sustainability

The Cook Quench Chill ‘Adapt’ system by DC Norris represents a significant leap forward in the food processing industry. Its innovative design, incorporating the patented Jet Cook™ technology and Variable Wave Agitation System, sets a new standard in cooking efficiency, product quality, and environmental sustainability. The system’s modular nature, energy-saving features, and water conservation capabilities demonstrate a deep understanding of the industry’s needs and challenges.

Empirical Evidence of Superior Performance

The trial data supports the system’s exceptional performance across a diverse range of products. With its ability to rapidly cook, quench, and chill various food items while maintaining precise temperature control, the ‘Adapt’ system proves to be not just versatile but also highly efficient. The significant increase in cooked weight per hour and the reduction in total process time are testaments to its productivity and effectiveness.

A Step Towards a Greener Future

In an era where environmental concerns are paramount, the Cook Quench Chill ‘Adapt’ system stands out as a beacon of sustainable innovation. Its reduced energy consumption and water usage align perfectly with the global push towards reducing carbon footprints and promoting eco-friendly industrial practices. By adopting this system, food processors are not only enhancing their operational efficiency but also contributing to a more sustainable future.

The Road Ahead

As the food processing industry continues to evolve, systems like the Cook Quench Chill ‘Adapt’ will play a pivotal role in shaping its future. With ongoing advancements and potential future enhancements, the system is well-positioned to meet the ever-changing demands of the industry. Its impact extends beyond immediate operational benefits, influencing broader trends towards sustainability and efficiency in food processing.

Invitation to Explore and Connect

We invite readers to delve deeper into the world of the Cook Quench Chill ‘Adapt’ system and explore its potential for their operations. For more information, detailed consultations, or to see the system in action, please reach out to the experts at DC Norris. Together, we can embark on a journey towards more efficient, sustainable, and innovative food processing solutions.