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NFS
48,3
468
Received 16 October 2017
Revised 26 December 2017
Accepted 1 January 2018
Nutrition & Food Science
Vol. 48 No. 3, 2018
pp. 468-482
© Emerald Publishing Limited
0034-6659
DOI 10.1108/NFS-10-2017-0222
Combined approach of COOK
CHILL with HACCP
Ana Valéria Toscano Barreto Lyra, Larissa de Arruda Xavier and
André Philippi Gonzaga de Albuquerque
Universidade Federal de Pernambuco, Recife, Brazil, and
Fagner José Coutinho de Melo and Denise Dumke de Medeiros
Department of Production Engineering, Center for Technology and Geosciences,
Universidade Federal de Pernambuco, Recife, Brazil
Abstract
Purpose – Food service demands a greater concern with food security, as around two million people in the
world, among them the majority of children, die from foodborne diseases. The purpose of this study deals
with the adoption of the COOK CHILL system, in the principles of the hazard analysis and critical control
point system (HACCP), within a food and nutrition unit of a petroleum refinery, to enable food security and
cost reduction operational services in food services by using the traditional method of food production. To do
so, hygienic-sanitary diagnosis based on Brazilian ANVISA standards is carried out.
Design/methodology/approach – The company that served as an object for the case study is an oil
refinery located in the northeast region of Brazil, divided into 55 units with a production capacity of 323.000
barrels/day. For reasons of confidentiality, it will be referenced throughout the text of this work as Refinery.
Findings – With the implementation of the system, it was possible to reduce operational costs, food waste
and energy and to provide safe food and increasing customer satisfaction.
Originality/value – The improvement achieved with the production of food quality was the adoption of
the COOK CHILL system in the application of HACCP through the use of value (D) to control the biological
CCP and monitoring through the control sheets.
Keywords Food safety, HACCP, COOK CHILL system
Paper type Research paper
1. Introduction
Food safety is one of the main responsibilities of the food industry and food services, their
quality and their sensory aspects. Safe and adequate food for consumption prevents the
spread of foodborne diseases, which can be fatal to humans (Food and Agricultura
Organization of the United Nations World Health Organization, 2006; Baldwin, 2012;
Carrascosa et al., 2016).
Thus, to ensure food safety, a system was created in 1959 by the Pillsbury company in
the USA namely, the hazard analysis and critical control point system (HACCP), whose
development was based on the failure, causes and effects analysis tool, using a philosophy
of prevention and control (Ribeiro-Furtini and Abreu, 2006; Cerf and Donnat, 2011; Demirci
et al., 2016). The HACCP system analyzes risks in food prevention through hazard analysis,
generating corrective actions to its deviations, such as personal and work environment
hygiene, satisfactory handling and urban pest control (Lau et al., 2016; Qianqian and
Harasawa, 2016; Trafialek and Kolanowski, 2017).
Allied to HACCP is the COOK CHILL system (Cerf and Donnat, 2011), helping to
establish critical limits for critical control points (CCPs) of a biological nature, specifically in
the steps of processes such as cooking, cooling and regeneration (already cooked foods, COOK CHILL
reaching food safety temperature again), and establishing monitoring procedures, CCPs, with HACCP
actions, corrective measures, registration procedures, documentation and verification, as the
traditional food production system does not have the technological or methodological means
to that end (Lacey, 1989; Kawasaki et al., 2007; Ribeiro, 2011; Tsui and Morillo, 2016).
The objective of this work is to analyze, through a case study, how the adoption of the
COOK CHILL system in the application of HACCP increases the food quality of a food and 469
nutrition unit of a refinery and what impacts and benefits these systems will bring to the
company. The research can serve as a basis for other companies wishing to work with the
use of these systems to ensure some advantages. By controlling time and temperature,
important results can be obtained from companies, such as food quality and cost reduction.

2. Methodology
2.1 Company scenario
The company that served as an object for the case study is an oil refinery located in the
northeastern region of Brazil, divided into 55 units with a production capacity of 323,000
barrels/day. For reasons of confidentiality, it will be referenced throughout the text of this
work as Refinery.
The Refinery has an outsourced food service with centralized and decentralized
distribution, providing the 55 units in operation. These units are operated by machines
supervised by qualified employees, who must be well nourished and healthy. However, this
reality was not present in the Refinery, which presented pictures of food outbreaks and
dissatisfaction with food quality.

2.2 Sanitary hygienic diagnosis

The sanitary and hygienic diagnosis of the Refinery Food Unit was carried out by means of
a checklist based on the checklist proposed by Resolution RDC n°0.275 of October 21, 2002,
of the Brazilian National Health Surveillance Agency (ANVISA) and the Resolution to RDC
n°. 0.216 of September 14, 2004, of ANVISA (ANVISA – Brazilian Health Regulatory
Agency, 2004, 2002).
The objective of the diagnosis should be to verify the hygienic sanitary conditions of the
establishment under study and from the observation of the following points:
 building, facilities, equipment, furniture and utensils;
 hygienization of installations, equipment, furniture and utensils;
 integrated vector control and urban pests;
 water supply;
 waste management;
 handlers;
 raw materials, ingredients and packaging;
 food preparation;
 storage and transportation of prepared food;
 exposure to the consumption of prepared food;
 documentation and registration; and
 responsibility.
NFS 3. Results
48,3 3.1 Analysis of the diagnosis of sanitary hygiene
After the hygienic-sanitary diagnosis of the refinery, the result found was 40 per cent of the
conformities and 60 per cent of the nonconformities hygienic-sanitary of the general aspects of
human resources, environmental conditions, facilities, buildings and sanitation, equipment,
sanitation, production and quality control. The analysis also allowed us to verify that the main
470 control point of the CCP was the time and temperature of the food production and its
distribution to the units in operation.
The daily production of the Food and Nutrition Unit was at least 700 kg of hot food,
consisting of beans, rice, garnish, cooked salads and proteins (meats). Unit of nutrition and
food was also responsible for the provision of desserts, raw salads and juices, which totaled
about 1 tonne/day to be produced and distributed, respecting the menu and local
gastronomy, meal times and food safety.
Another point was that all meals were produced early in the morning, close to the time of
distribution; it was often identified that the food was initially distributed to 60 per cent of the
units in operation, and the remaining 40 per cent came later, generating a 30 per cent
production waste per day, as meals were self-service and did not work with a history of
daily demand. The production was always greater, as a way to avoid the lack of meals in the
units, according to the outsourced company.
There was also general dissatisfaction among Refinery employees for non-compliance
with the menu, disrespect for mealtime and occurrence of foodborne illness cases, favoring
consumer risk.
In view of the above, the implantation in the Food Analysis Service, HACCP and the
COOK CHILL system, at some stages of the production process, would alter the established
chaos scenario, bringing gastronomic and food safety benefits to the users and financial and
operational advantages for the Refinery.

3.2 Implementation of the COOK CHILL system at the Food and Nutrition Unit
For the implementation of the COOK CHILL system, it was necessary to plan the processes
throughout the production chain and the HACCP management that would be used in the
Refinery to ensure food safety in accordance with the Department of Health (1989); this
process is presented in the discussion section.
After establishing the organization and management project of the HACCP and COOK
CHILL system, the system is implemented with the following steps:
 Step 1: it consists of understanding of the flow chart of the COOK CHILL system.
 Step 2: it consists of the use in each process of the flow chart of the COOK CHILL
system.
 Step 3: it is the application of the steps that make up the COOK CHILL system in the
system flow chart.

The structuring of the implementation of the COOK CHILL system in the Food and
Nutrition Unit can be observed in Figure 1.

4. Discussion
The planning of processes throughout the production chain and the HACCP management
used in the Refinery for the implementation of the COOK CHILL system is presented in
Table I.
 COOK CHILL
with HACCP

471

Figure 1.
Implementation of the
COOK CHILL system
in the food and
nutrition unit

After establishing the organization and management project of the HACCP and COOK
CHILL system described in Table I, the system is implemented with the following steps:
 Step 1: it is the understanding of the flow chart of the COOK CHILL system, as
shown in Figure 2, which should be used for all product groups necessarily
following the flow direction.
 Step 2: it is the use in each process of the flow chart of the COOK CHILL system, the
hygiene rules recommended by the manual of good practices of manipulation and
production of foods.
 Step 3: it is the application of the steps that make up the COOK CHILL system in the
system flow chart.

These steps will be described below.

4.1 Cooking
The cooked foods were divided into groups, taking into account the type of cooking, the
time/temperature relationship (Value D), and the microorganisms involved in a possible
contamination, as presented in Table II. The monitoring was done through a cooking
spreadsheet to generate corrective actions in the event of possible deviations. According to
Lima et al. (2017), the binomial time/temperature is sufficient to eliminate biological agents
that compromise food safety in cooked foods.
The microorganisms involved were extracted from RDC No. 12 of January 2, 2001
(ANVISA – Brazilian Health Regulatory Agency, 2001). It should be emphasized that food
does not undergo full cooking, as food will be reheated in the regeneration stage.

4.2 Wait after cooking

In this step, the foods that have been cooked must reach 60°C in their Geometric Center to be
brought to the refrigeration in the blast chiller chamber (cell), according to RDC norm 216
(ANVISA – Brazilian Health Regulatory Agency, 2004). The control point to be monitored is
NFS
Objective Strategy Strengths Weaknesses
48,3
1. Raise food 1.1 Application of hygienic- The outsourced company No concern about food
safety and sanitary check list for initial Training of employees of safety by the outsourced
produce menu diagnosis of food safety the outsourced company company
1.2 Collection of information of the The absence of inspection
menu uded to generate information to
472 the quality system Lack of
motivation for
improvements in the
menu
Collaborators not trained
2. Raise critical 2. HACCP Analysis of biological, Lack of good production
process steps chemical and physical practices
hazards
3. Monitor the 3.1 Analysis of the feasibility of Time and temperature of The distance between
time and the COOK CHILL system in the production and operating units
temperature of cooking, cooling and regeneration distribution
production and stages
distribution
4. Survey of 4.1 Loading and measuring Machinery, size and People do not work with
machinery and equipment required for the layout of the production food safety
environment HACCP and COOK CHILL system area Precarious physical
4.2 Size of production area structure and equipment
The absence of equipment
to realize the system
5. Work on 5.1 Confirmation of the direction Understanding of food Conflicts of interest
commitment of the company safety
5.2 Signature of the Term of
Agreement with the Methodology
5.3 Elaboration of the
commitment letter
5.4 Understanding and
commitment of the employees
involved
6. Plan the 6.1 Definitions of food groups that Focus on production Acceptance of the system
COOK CHILL will be cooked, cooled and
system regenerated
6.2 Elaboration of the Productive
Framework with the respective
weekly schedule
6.3 Planning daily production
with a margin of safety to avoid
waste
6.4 Elaboration of COOK CHILL
system flow
6.5 Elaboration of the
Management System Worksheet
and Verification of the Production
System
Table I. 6.6 Elaboration of time and
Organization and temperature control sheets in the
management of cooking, cooling and regeneration
HACCP and COOK stages
CHILL (continued)
 COOK CHILL
Objective Strategy Strengths Weaknesses with HACCP
7. Design and 7.1 What tasks should be Human resources Understanding and
organization of allocated to each employee in the Understanding of the acceptance
work operation productive process
7.2 What sequences of tasks
should be established to 473
accomplish the job
7.3 Where work must be allocated
within the production process
7.4 That Food Service sector and
operators should be involved with
the work
7.5 Definitions of how facilities
and work equipment should be
7.6 Defining the skills to be
developed in the collaborators
8. Carry out 8.1 Capacitation of the employees Unify the information Understanding and
training involved Breaking paradigm acceptance
courses
9. Implantation 9.1 Deployment by product Improvement in food Paradigm break
of the COOK groups production and food
CHILL system quality
in the
production of
Refinery meals Table I.

the temperature of the food during the post-cooking wait. The temperature in the Geometric
Center should reach room temperature (26°C). To facilitate the exit of heat, the food must be
fractioned in gastronomic vats.

4.3 Cooling
At this stage, the food is cooled in a chamber called blast chiller (cell), reducing the
multiplication of Clostridium botulinum; and Bacillus cereus and its sporesm would be
controlled because they belong to the group of mesophiles (Kawasaki et al., 2007). The
control point to be monitored is the temperature of the food cooling. With regard to cooling,
it is not advisable to let the food freeze inside the cell. Food must be chilled in small portions
so that they are cooled completely in a short period (Franco and Landgraf, 2008).

4.4 Refrigerated storage

After cooling in the blast chiller, the food is stored in the cold storage chamber. As exposed
by Dincer (2017), the cold is widely used in the preservation of perishable foods, both animal
and vegetable origin, and basically preserves food because it slows down or inhibits
microbial multiplication.
The control point to be monitored is the temperature of the conservation chamber, and
this monitoring takes place in the two work shifts (morning and afternoon) through a
temperature control worksheet. This control is necessary to ensure that stored food is kept
at 4°C, keeping the microbiological metabolism low and avoiding food contamination.
NFS
48,3

474

Figure 2.
COOK CHILL system
flow chart

Groups Foods involved Microorganisms involved Temperature (°C) Value D (minutes)

Group A Fish, shrimp, seafood, eggs Salmonella species; >74 10

Staphylococcus aureus;
Coliforms to 45°C
Group B Pork Salmonella species >65 1
Group C Beef Salmonella species; >74 10
Staphylococcus aureus;
Coliforms to 45°C;
Clostridium
Group D Chicken Coliformes to 45°C >74 10
Group E Other food groups Salmonella species; 74 10
Table II. Staphylococcus aureus;
Product groups and Coliforms to 45°C;
their respective Clostridium;
value D B. cereus

The care in this step is that the food entering the storage chamber should be capped and
labeled with production date and validity and separated by the batch of regeneration,
namely:
 First lot: food transported (“hot-packs of aluminum for individual consumption”).
 Second lot: food service (self-service).

As under-refrigeration conservation cannot be considered as a way of eliminating

microorganisms, the shelf life of the food in the chamber and the temperature being
preserved are monitored (Diaz, 2009). Therefore, the following aspects should be taken into COOK CHILL
account: with HACCP
 The shelf life of food under preservation is up to 05 days.
 The temperature of the storage chamber is set at 2°C (set point).
 The temperature in the Geometric Center of the food under conservation is less than
or equal to 4°C.
 The vats should be placed on shelves or skeleton type carts and should be kept
475
away from each other and from the wall for better air circulation.
 The vats should be disposed of in a rational and practical manner, allowing easy
storage and validity checking.
 The food is delivered according to the validity deadlines, allowing the operation of
the first in and first out system.

4.5 Regeneration
At this point, foods that have already undergone initial cooking must reach the food safety
temperature again and are reheated through the use of combined oven heat. This step
should occur immediately after leaving the conservation chamber. Regeneration, if used
properly, is a special process and very efficient in reheating preparations ready for
consumption, maintaining their sensory characteristics and avoiding microbial
contamination (Gaze, 2005; Food Safety Authority of Ireland, 2006).
The CCP to be monitored is the final temperature of the regenerated foods of the Product
Groups. This temperature is in accordance with the standard requirement of the critical
limits established in the HACCP Plan, for this step to be a CCP. The regeneration
temperature is above 74°C in the Geometric Center of the food at the end of its reheating for a
maximum of 5 min. Regeneration is divided daily:
 First lot: food transported (“hot”).
 Second lot: food service (self-service).

4.6 Maintenance
At this stage, hot foods are kept warm before their centralized or decentralized distribution.
This maintenance is performed through the use of equipment such as the water bath and/or
pass thought. The critical point of control to be monitored is the internal temperature of the
maintenance equipment and the temperature in the Geometric Center of the food of the
Product Groups during its maintenance. This monitoring is in accordance with the standard
requirement of the critical limits established in the HACCP Plan, for this step to be a CCP.
The recording of the monitoring is done by completing the equipment and food
temperature control sheet, which is necessary to avoid the growth of microorganisms before
their distribution (Rodgers, 2003). Regarding this step, it is important to note that the
following:
 After being regenerated, the transported foods remain in the water bath above 60°C
in the Geometric Center. For this to occur, the temperature of the water bath is at a
temperature above 80-90°C during the installation of the hot water.
 The vats are kept capped prior to assembly to maintain the temperature of the food
transported.
NFS  If the regeneration is completed before 10:00 a.m., as this is the time for the
48,3 assembly of the hot foods, the food is kept in the combined oven or in the oven with
temperature above 60°C in its Geometric Center.
 Food in the refectory, after being regenerated, is immediately packed in the cafeteria
hall ramp at a temperature above 60°C in the Geometric Center for a maximum of
6 h or kept warm inthe “pass through” (transport equipment that maintains the
476 characteristics of hot or cold meals) also at a temperature above 60°C in the
Geometric Center.
 The water bath and the pass through are connected 2 h before the installation of the
little tops and vats used on the ramp of the dining room near the central kitchen.

4.7 Distribution
In this step, foods are exposed for immediate consumption but under time and temperature
control to maintain safety. The critical control point to be monitored is the food temperature
of the Product Groups of the refectory and the food transported during its distribution. This
monitoring is in accordance with the standard requirement of the critical limits established
in the HACCP plan, for this step to be a CCP. The monitoring record is done by filling out the
distribution temperature control worksheet.
To carry out all the steps described above, good food handling practices are performed as
they help to reduce and avoid microbiological, chemical and physical hazards in food. Food-
bearing surfaces can be sources of micro-organisms if they are not cleaned properly. In this
way, they should be treated only with personnel with good personal hygiene (Chavasit et al.,
2011). Best practices are a prerequisite for the implementation of the COOK CHILL system
and its subsequent operationalization.
For implementing the COOK CHILL system, which is based on complete cooking of
foods, followed by rapid cooling and storage under controlled conditions of low temperature
(Fusi et al., 2016), besides the knowledge of the processes that comprise it and its food safety
criteria, it is necessary to:
 know the flow chart of production processes to identify the steps that make up the
COOK CHILL system;
 understand the cooking stage as the center point of the COOK CHILL system, using
it as a guideline for the execution of the other stages that make up the system;
 know the composition of the daily menu offered;
 know the Product Groups (A, B, C, D and E) that will be operationalized by the
system; and
 know the Daily Produced Table of Served Meal (weekly schedule), described in
Table III, which is a necessary tool for the weekly programming of some productive
stages that make up the COOK CHILL system to be executed.

To reduce the operating costs of cooking, lunch and dinner will be held together, but lunch
will be regenerated the next day and dinner the same day. The COOK CHILL system flows
described below in Figure 3 represent the inputs of the cooking and regeneration steps and
outputs from the cooling stage of the Productions of the Product Groups in the system and
their respective setup times, based on the daily production schedule (Table III).
In Flow 1, the cooked salads, garnish and optional protein on the menu (for 40
per cent of the total served) are cooked on the day prior to consumption or up to five
days. Regeneration of the Product Group linings are on the day of their consumption. In COOK CHILL
Flow 2, the main protein of the menu is cooked (60 per cent of the total served) and the with HACCP
regeneration of the main and optional proteins that were cooked the day prior to its
consumption or up to five days. In Flow 3, the cooling of all the items that were cooked
in Flows 1 and 2 is performed.
In all flows, the entrance and exit times of the machines are respected at every
entrance and exit of the food so that the temperatures, the scheduled production times
and the schedules of the operators are aligned, avoiding the presence of overtime and 477
increase in consumption of energy, gas, among others.
The COOK CHILL system starts daily at Flow 1 at 7:30 a.m. and ends at Flow 3 at 5:20
p.m. and is operated by four operators allocated as follows:
(1) Flow 1. This is the stage of catching salads and garnishes, an operator is allocated
for the regimentation of the garnishes.
(2) Flow 2. Cooking of the protein stage (option) was allocated by an operator.
(3) Flow 3. For this stage of cooking of the protein (main) and of protein regeneration
(main and option), we chose to allocate an operator.
(4) Flow 4. Freshings of garnish and protein stage was allocated by an operator.

Days Prep Cooking Regeneration

Monday Wednesday Tuesday Monday

Tuesday Thursday Wednesday Tuesday
Wednesday Friday Thursday Wednesday
Thursday Saturday Friday Thursday
Friday Sunday Saturday Friday Table III.
Saturday Monday Sunday Saturday Daily production
Sunday Tuesday Monday Sunday (weekly schedule)

Figure 3.
COOK CHILL
system flow
NFS Menu items such as beans and rice are outside the COOK CHILL system and the said flows
48,3 are produced by the traditional cooking system on a daily basis in industrial panels, and the
operator allocated for this function is the same one allocated in Flow 1.
It is important to point out that any deviation in the time and temperature in each equipment
in the above flows, due to lack of preventive and/or predictive maintenance, makes the
system unfeasible and consequently generates overtime in the operational framework,
478 dissatisfaction, lack of credibility in the system, possible microbiological contamination and
delays in the distribution of meals to the diners.
It is necessary to know the emergency corrective actions due to the occurrence of any
problems that may make the system unfeasible:
(1) The problem in Blast Chiller (cell):
 Call for maintenance with EMERGENCY and identify the cause of the problem.
 Expunge all foods that have not been cooled.
 Return to the traditional cooking system until normality is established.

(2) The problem in the combined oven:

 Call for maintenance urgently and identify the cause of the problem.
 Perform the regeneration step in the industrial stove, frying pans or in the
panes and to be determined as reheating.
 Check the reheating temperature which should be above 74°C in the Geometric
Center of foods.
(3) The problem in the conservation chamber:
 Call for maintenance with EMERGENCY and identify the cause of the problem.
 Remove all food from the inside of the camera and temporarily hold it in
another chamber with the same internal temperature at 4°C.
(4) Problems with the equipment for maintenance of the heated foods (bath-water and
pass thought):
 Call for maintenance with EMERGENCY and identify the cause of the problem.
 Keep foods heated above 60°C in the Geometric Center, even in the combined
oven.
Problems of maintenance in the equipment and failures of another nature as the absence of
food in the area of production, equipment and others can occur; and as a way to minimize
these failures due to lack of food, equipment and others in the productive stages of the
COOK CHILL system, a production tool that identifies and corrects these problems, called
production system verification, must be used. Is used in the production area to measure the
time of each process of the COOK CHILL system based on the initial and final production
time and on the absence or lack of food, equipment or other, enabling satisfactory
production in each process.

5. COOK CHILL system in cost reduction

According to Shanaghy et al. (1993), the main cost reduction of the system is with foodborne
diseases, but other reductions are also identified with the adoption of the COOK CHILL
system in the application of HACCP:
  reduction of the operational framework through production planning and balance; COOK CHILL
this reduction was approximately 46, a reduction of six employees; with HACCP
 increase and addition of the preparations produced in the cooking area and
served in the refectories of the Refining units, distal and proximal, the central
kitchen;
 reduction of approximately 2 h in the cooking time in the product group
preparations, because of the reduction in the work shift and the production being 479
modulated, that is, each operator produces its food group according to the flow of
the COOK CHILL system; this result as an unfolding, reduction of daily
consumption of steam, electricity, water and man-hour (Mh);
 balancing production through operational allocation;
 reducing waste, only regenerating foods that are necessary to the demand of diners,
that is, being able to use food stored in refrigerated storage (shelf life of five days) if
it increases the demand of the diners;
 elimination of seven production wastes, namely, excess production, where the waste
in the Refinery daily after the lunch meal was on the order of 30, over 1 ton of meal
produced; transactions; reworks; high stocks; unnecessary transport; waiting time;
and inadequate processing; and
 creation of cooking, cooling and regeneration workstations, with their inputs
planned and verified by the VSP worksheet, promoting outputs with food quality
and low operating costs.

6. Improvements obtained with the COOK CHILL system at Food and Nutrition
Unit
The organization and management of the HACCP and COOK CHILL system implemented at
the Refinery brought to the company some improvements such as:
 the undoubted advantages of the COOK CHILL method for centralized production
systems in terms of the food safety aspect (however, the intrinsic risks to the
system, which requires strict time and temperature control in the production stages,
must be considered) (Kawasaki et al., 2007);
 increased supply of items on the menu, respecting eating habits, without burdening
production;
 reduction of waste with inputs and ready meals;
 increase in the quality of the work of managers and their supervisors;
 better oriented manipulators in the daily activities of food production;
 contribution in reducing costs, which corresponds to an increase in productivity
with quality and safety (Yoshida, 2015);
 institutional gain, as it values the work of the team and increases the self-esteem of
its members, the people involved become aware of what they do and why they do,
gaining self-confidence and satisfaction by producing food with a high level of
security; and
 reduction in the need for testing finished products for the determination of
microbiological contaminants.
NFS 7. Conclusions
48,3 The central objective of the case study is to demonstrate that the implantation of the system
brings significant improvements in food quality from the microbiological point of view, but
also that the improvements achieved transcend the biological field and satisfy the operator
by increasing their productivity, improving the quality of life in work and tranquility in
production. Improvements in the operation, such as: speed, scheduling and menus,
480 gastronomic improvement, reduction of waste, production scheduling and organization of
the work environment. Finally, improvements for the consumer from the point of view of the
fulfillment of the meals served, quality of the food, gastronomy and sensorial.
The improvement achieved with the production of food quality was the adoption of the
COOK CHILL system in the application of HACCP through the use of Value (D) to control
the biological CCP and monitoring through control sheets. However, depending on the
intrinsic factors that influence the thermal resistance of microorganisms and determine
the nature of the physic-chemical composition of the food (fat content, pH, among others), at
the end of the cooking stage, there will be the possibility of the presence of thermoresistance
microorganisms, remaining from this stage as bacterial spore-forming C. botulinum and B.
cereus. For this reason, the post-cooking processes must be controlled to prevent the
remaining microbial growth and the germination of their spores in the food.
Within the context, the use of the system can also be cited as a guarantee of a longer shelf
life, thus prolonging its shelf life for months, which consequently results in a time saving.
With this, the system collaborates with the production output flows and gives agility to the
service.
Gastronomic improvements have been presented as benefits that the system
generates to Food Service processors and operators because it is practical, dynamic and
flexible.
The technology of the COOK CHILL system is easy to implement but does not exempt a
qualified technician. It needs controls of its operationalization to meet the expectations of the
food quality, without risks to the company and to the diners (consumer).
It is recommended in to verify the Statistical Process Control of the COOK CHILL system
in the company, the probability of occurrence of these microorganisms in their reservoirs
and new studies to develop a technology of elimination of these microorganisms in Food
Services in the foods involved.
The difficulties encountered in the execution of research were the distance from the
Refinery to the data collection and the specific literature on the cold chain from the point of
view of inactivation in the food reservoirs of C. botulinum and B. cereus through the use of
time and temperature of the system technology COOK CHILL. There is a lot of system
advertising, but little scientific work on the subject, for research.
The limitations were the microbial elimination of the bacteria C. botulinum and B. cereus
and their spores, which may be present in preparations that reach a cooking temperature of
less than 100°C in its Geometric Center. These pathogenic bacteria are important etiological
agents transmitted by food, have their evident epidemiological characteristics and are
eliminated in the industrial area, but not always in the Services food, and can compromise
human lives, especially in the case of C. botulinum, for which one of the symptoms of its
clinical condition is respiratory paralysis and death.

References
ANVISA – Brazilian Health Regulatory Agency (2001), “Ministerial resolution – RDC N.12, 2 February
2001”, available at: http://portal.anvisa.gov.br/contact-us (accessed 24 March 2017).
ANVISA – Brazilian Health Regulatory Agency (2002), “Ministerial resolution – RDC N. 275, 21 COOK CHILL
October 2002”, available at: http://portal.anvisa.gov.br/contact-us (accessed 25 September
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Further reading
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Stationery Office, London.
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portalsaude.saude.gov.br/index.php/cidadao/principal/english (accessed 24 march 2017).

Corresponding author
Fagner José Coutinho de Melo can be contacted at: fagnercoutinhomelo@gmail.com

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