Download Blast Chiller User Manual

Notes:
TURBOQUIP BLAST CHILLER
The primary usage of the Turboquip Blast chiller is for effective bacteria
management. The blast chiller will bring protein based food products from
temperatures above 120°C to the safety zone below 7°C in a shortened time
frame thus eliminating the generation of bacteria. Bacteria generate between
7 and 65°C, and double in quantity every 20 minutes. Leaving food at room
temperature to cool down is the primary cause for food poisoning.
The blast chiller can also be used for blast freezing.
THE CONTROL PANEL:
A
B
C
D
E
F
G
H
I
J
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-
ALARM
BUZZER
POWER
ON/OFF SWITCH
PROGRAM BUTTON “UP”
PROGRAM BUTTON “DOWN”
DIGITAL DISPLAY
INDICATES REFRIGERATION
INDICATES DEFROST IN PROCESS
INDICATES FAN IN OPERATION
1
INSTALLATION
THERMAL QUALITY OF CONTAINERS
IMPORTANT!!
Do not push the blast chiller up against the wall, the unit needs at least 150
mm for the hot air to escape from the compressor.
Install in a well-ventilated area, preferably away from any cooking equipment.
Ensure that the drip tray at the rear of the unit is under the drainage pipe and
secure.
10.0
10
9
Ensure the interior probe is not entangled in the fan.
8
OPERATION
7
1.
Ensure unit is plugged in and switched on at the wall.
6
2.
The control panel and on/off rocker switch will illuminate.
3.
Turn rocker switch to on position.
4.
Before commencing with operation, the unit is set up for blast chilling and
not blast freezing in the factory. Therefore the control panel will regulate
refrigeration until the core temperature of the product reaches +9ºC. This
maintains the surface temperature of approx +4ºC, which is a bacteria
safe temperature.
5.
Should you wish to reset the core temperature, the procedure is as
follows:a. Depress both “E” & “F” simultaneously.
mark
Plug the unit into a 15 AMP wall socket.
7.7
5.1
5
4
3
2
1.2
1
0
stainless stell
polypropylène heatpolycarbonate
formed
ABS
The set point temperature is then displayed.
b. Toggle up with “E” and down with “F” until reaching desired set point.
c.
Depress both “E” & “F” simultaneously to confirm setting.
d. After 5 seconds the unit will return to normal operation.
e. To check settings, depress “E” & “F” simultaneously then wait 5s.
2
21
RECOMMENDED FOODSTUFF PACKAGING
6.
Blast Freezing In order to blast freeze a product the controller should
be set at a temperature of –10ºC. This will facilitate complete
deactivation of bacteria multiplication. The resultant surface temperature
should be ± (-18ºC)
To activate this cycle, follow steps “a-e” above.
BLAST CHILLING:
As previously mentioned the unit is set up to blast chill the core of the product
to a temperature of 10ºC.
1. Place product from cooked state of 65ºC or greater in a stainless steel
container of no deeper than 65 mm in the blast chiller rack.
2. Insert the core probe into the centre of the food.
3. Fill rack to no more than 10 trays with core probe inserted into largest of
products.
4. Large joints of meat should be placed in shallow trays or on flat surfaces
for most effective cooling, with the core probe inserted into centre of
product.
5. Close door and ensure rocker switch ”D” is in “ON” position.
6. Wait for buzzer to sound.
7. Depress “D” to silent buzzer. The controller will display:
a. A1 Low Temperature Alarm
b. A2 High Temperature Alarm
150 mm
8. Switch rocker switch to “OFF” position.
9. Remove product from Blast chiller and refrigerate
MAINTENANCE
1. Unit should be switched off at the wall when not in use.
2. Condensation tray at the rear of the unit should be emptied after every
cycle. And replaced to original position.
3. The tray rack can be removed for cleaning in the event of spillages.
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4. Ensure front breather panel is kept clean and free from obstruction
allowing adequate ventilation.
3
TROUBLE SHOOTING GUIDE
PROBLEM
POSSIBLE CAUSE
SOLUTIONS
1. Unit does not switch
on and power light
does not illuminate
a. Not plugged in
a. Plug in to power
supply
b. Faulty power cable
c. Electrical supply
b. Call technician
IMPACT OF AIR TEMPERATURE LIMITATION
UPON PERFORMANCE
Blast Chilling test performed with 25 kg of mashed potatoes
(14 covered containers of 1.8 kg each)
c. Call electrician
2. Neon power on light
illuminated but blast
chiller does not
operate
a. HP-LP switch tripped
a. Reset by
b. Blocked Condenser
b. Clean and clear
obstructions at the
rear of unit
c. Faulty condenser fan
d. HP switch faulty
e. Gas leak
c. Replace fan
d. Replace switch
e. Call Technician
3. Unit runs but does
not refrigerate
a. Faulty compressor
b. Faulty solenoid
c. Faulty expansion
valve
Call service technician
d. Loose wiring
a. One fan not working
b. All fans faulty
111
92
-20°C
e. Controller
programming
4. Fans inside cabinet
not running
120
100
80
time
60
(minutes)
40
20
0
0°C
air temperature limitation
a. Faulty fan or loose
connection to fan
b. Faulty on/off switch
c. Faulty controller
d. Unit in defrost cycle
4
19
IMPACT OF END OF CYCLE CORE TEMPERATURE
UPON PERFORMANCE
Blast Chilling test performed with 25 kg of mashed potatoes
(14 covered containers of 1.8 kg each)
Duration of cooling from 65°C, core temperature
APPLICATIONS
All foodservice operations are faced with varying production demands, such
as, time constraints, labour challenges, a need to control food costs and
ensure safety. Blast chilling addresses all of these daily concerns with the
additional benefit and piece of mind of safety.
•
Blast Chillers are one of the most versatile pieces of equipment
available today.
•
This equipment can be used to blast chill raw, par-cooked, or fully
cooked foods.
•
Blast Chillers compliment all other major pieces of Turboquip
equipment. Foods can be blast chilled before or after using Turboquip
cooking or holding equipment.
“Cook-Chill” is a relatively new concept in food preparation for retail
foodservice operators. A concept that has gained popularity due to the
reduced costs of implementation, substantial flexibility gained in menu variety,
labour usage, and the increased concerns for food safety by consumers.
2
1.5
time
(houres)
1
1.6
2
The time foods spend in the temperature “danger zone” 5°C - 60°C directly
contributes to the growth and spread of contamination. Therefore it is
important to quickly move foods through the danger zone and monitor the
time necessary to do so.
0.5
0
+10°C
+3°C
End of cycle core temperature
18
5
ADVANTAGES TO RAPID CHILLING
IMPACT OF CONTAINER’S COVER
UPON PERFORMANCE
There are several food characteristics, which are effected by the cooling
process. The ability to minimize the time foods are allowed to spend in the
danger zone impacts these characteristics. Below is a list of advantages to the
rapid chilling of foods:
Blast Chilling test performed with 25 kg of mashed potatoes
(14 containers of 1.8 kg each)
Texture
•
Minimizes the loss of moisture
•
Minimizes the softening of food product resulting from pectin
breakdown
•
Minimizes the growth of bacteria and molds contributing
breakdown of product tissue
to the
Duration of cooling from 65°C, core temperature
Nutrition
•
Reduces vitamin loss (ascorbic acid and thiamin most susceptible)
Color
•
Preserves rich and bright colors (rapid cooling reduces the
Enzymatic action which facilitate the loss of color)
Flavor
•
Preserves the desired flavor through the reduction of psycrophilic
bacteria and molds
2
1.5
time
(houres)
1
1.6
2
0.5
0
+10°C
+3°C
End of cycle core temperature
6
17
IMPACT OF FOOD THICKNESS
UPON PERFORMANCE
Tests performed by University of Bristol, UK
bolognese sauce, air flow 3 m/s, air temperature stable at -2°C,
covered containers
6
5
4
time
3
(hours)
2
1
0
WHY TO USE A BLAST CHILLER / FREEZER?
•
To serve safe food
•
To be in accordance with regulation and / or HACCP program
•
To increase shelf life
•
To increase production capacity
•
To help some kitchen works
•
To permit variety and / or menu expansion
•
To reduce labour cost
•
Because cold cabinet is not designed to chill hot food
5.9
2.7
0.7
10 mm
40 mm
80 mm
Thichness of food
16
7
ACTION OF TEMPERATURE ON THE MICRO-ORGANISMS
destruction of all bacteria (sterilisation)
destruction of vegetative forms
(pasteurisation)
destruction
75
65°C
45°C
20°C
Danger
Zone
range of development of
most dangerous micro-organisms
From 5°C to 60°C
temperature (°C)
120°C
100°C
PRINCIPLES OF HEAT TRANSFER
Core temperature
65
55
conduction
Covered container
45
35
convection
25
Air flow
15
3.3°C
0°C
8
end of risk from the most dangerous bacteria
0
5
10
time (minutes)
-10°C
bacterial multiplication ends
-18°C
stop
Inactivation
without
destruction
15
Container surface
temperature
Air temperature
15
HEAT TRANSFER SURFACES
GERM MULTIPLICATION
BY PRODUCT TEMPERATURE
Cooled
Cooledsurfaces
surfaces
Air
flow
nomber of germ
Air
flow
500
450
400
350
300
250
200
150
100
50
0
25°C
20°C
15°C
10°C
0
5
10
time (hours)
Number at start: 5
14
15
Sanitation level of
staphylococcus germ
(rule dated 26 June 1974)
9
EUROPEAN REGULATION
COMPARISON OF DIFFERENT TYPES OF COOLING
OVER DURATION OF COOLING
1.8 kg of mashed potatoes in covered containers
WARM WAY
COOK AND CHILL
ITEM #III
germConsumption
multiplication
at another site
CENTRAL KITCHEN
(particular agreement)
70
Core temperature
60
core temprature (°C)
ITEM #I
Consumption
on the same day
ITEM #II
Postponed consumption
and
Consumption on
another site for
small quantities
50
40
one container (1.8 kg) in a room at 23°C
30
one container (1.8 kg) in a cold cabinet
20
10
blast chiller full loaded (3.5 kg to 660 kg)
0
0
1
2
3
4
5
6
7
time (hours)
10
13
COOK AND CHILL SYSTEM
based on European regulation
WARM WAY
COOK AND CHILL
SAFE FOOD AND LONGER SHELF LIFE
HEALTHY FOOD
AND
NO CONTAMINATION
(chilling does not cleanse)
2 hours
Maximum
4 days
Maximum
COLD MAINTAINED ALL TIME
EARLY USE OF CHILLING
(to avoid germ multiplication)
1 hour
Maximum
12
BLAST CHILLING
11