Pie & Pasty Filling Trials with Jet Cook

Over the last 7 days we have ran product trials with two large pie producers based in the UK, one mainly producing for supermarkets and the other both own label and brand.  The larger of the two companies are looking to cook and cool 2,000kgs of filling per hour with approximately 60 SKU’s. 

Pie fillings are one of our favourite products, and we were delighted to have two customers running trials of very different products.

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Steak & Onion – meat content 40%

Method: Capkold Cook Chill System, consisting of: Jet Cook, Braising Bar,  Pump Fill Station and Tumble Chiller

Result:

Cooking  - 50% quicker than traditional methods.

Cool Time -  70 minutes (below 5°C)

Excellent finished product quality. 

Traditional Pasty filling -25% meat content, vegetables, seasoning  and water.

Method:Capkold Cook Chill System - Jet Cook & Braising Bar Systems, Pump Fill Station & Tumble Chiller

Filling was cooked then discharged via our Pump Fill Station into 6kg bags before being cooled via Tumble Chiller.

Result:

Cook Time -  60 minutes   

Traditional processing time - 120 minutes

Cool Time – 80 minutes (below 5°C)

Good finished product quality and zero burn-on, which can be an issue with this type of product.   

Chicken & Mushroom Filling – 40% meat content

Method:

In-Tank Jet Cook

Challenge:

Due to the dairy content and viscosity there are typically burn-on issues.

Result:

Cook Time – 35 minutes

Traditional Processing time – 60 minutes

No burn-on

100% yield

Starch reduction - 20% / target viscosity achieved.

Corned Beef Slice Filling

Method:

Capkold Cook Chill System – In-Tank Jet Cook, Pump Fill Station & Tumble Chiller

Filling was cooked then discharged via our Pump Fill Station into 6kg bags before being cooled via Tumble Chiller.

Challenge:

Getting even distribution of ingredients due to the extreme viscosity of the product, reducing burn-on and discharging via a pump fill station   

Result:

Cook Time – 35 minutes

Traditional Processing time – 120 minutes

100% Yield

Burn-on reduced to a small amount that was washed off easily with cold water.

Finished product had an even distribution of both vegetables and meat.

Product successfully discharged via Pump Fill Station

Cool Time: 70 minutes (below 5°C)

Summary:

The Traditional Pasty and Corned Beef fillings were the most challenging products in terms of final product viscosity. Both the products had a hot viscosity of between 100,000 and 150,000 cP.  However using both Jet Cook and the Steam Jacketed Vessel, we successfully cooked and pumped the product without damage to the particulates. 

If you would like more information on our Jet Cook System for the production of Pie Fillings, or any other products then please contact us:

[email protected] / +44 (0) 1767 677515

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