Enhancing Culinary Excellence with DCN Jet Cook & Braising Bar

Client Overview:  Our valued customer is a prominent player in the food production industry. DCN’s dedicated Jet Cook product and process team visited for a two day product and process immersion at their site in Poland.

Objective:  To optimise their culinary processes using the DCN Jet Cook system and our innovative Braising Bar. This article delves into the transformative journey of elevating soup and Thai food quality through innovative technology and culinary expertise.

Challenge:  Our client faced the challenge of enhancing the flavour profile and efficiency of their soup and Thai food production processes. They sought to elevate the taste and texture experience of their offerings, whilst improving production speed and resource utilisation.

Solution – Jet Cook and Braising Bar Integration:  Our team implemented a comprehensive solution integrating the Jet Cook system and the revolutionary Braising Bar. The key components included:

Braising Bar Application:  The Braising Bar played a pivotal role in the process.  It enabled the searing and sweating of onions and vegetables before cooking, significantly enhancing the flavour profile of the soup base.  This step was a departure from conventional boiling methods.
Flavour Chemistry Unleashed:  We explored the science behind flavour chemistry.  We focused on vegetables with their rich aromatic molecules nestled within watery cells.  When subjected to the controlled heat and agitation of the Braising Bar, the cells ruptured releasing aromatic compounds.  The resulting flavour compounds merged to create entirely new and enticing taste experiences.
Thai Cuisine Mastery:  Our experts emphasised the significance of unlocking flavours at the outset of Thai cuisine preparation.  Cooking spices and onions in the early stages was highlighted as crucial. This foundational step paved the way for the vibrant and captivating flavours and crunchy textures that characterise Thai dishes.
Jet Cook Technology:  After flavour extraction, our Jet Cook Technology took the reins. The rapid cooking and heating maintained ingredient integrity and texture, a marked improvement over traditional steam jacket cooking methods.

The time required to heat 900 kgs of liquid to 92°C was reduced from 45 minutes to 15 minutes, resulting in significant energy savings.

Results – Culinary Excellence Unleashed:

Enhanced Flavour Profiles: The Braising Bar’s innovative application led to soups and Thai dishes with noticeably sweeter, richer, and more well-rounded flavour profiles.
Scientific Advancement: Understanding the science of flavour chemistry empowered our client to unlock previously untapped culinary possibilities.
Efficiency Gains: Rapid heating with Jet Cook reduced cooking time, leading to increased production efficiency and substantial energy savings.
Texture and Nutrition Preservation: Jet Cook Technology maintained ingredient textures and nutritional integrity, eliminating issues like burn-on or coconut milk denaturing.
Versatility: The Braising Bar’s adaptability, with six direction/pause options and variable speed settings, provided our client with creative flexibility in culinary creations.

Conclusion:

This illustrates how the collaboration between DCN’s Jet Cook product and process team and the customer in Poland resulted in a transformative culinary journey.  By harnessing the potential of Jet Cook and the Braising Bar, our client achieved enhanced flavour, efficiency, and culinary excellence.  If you’re seeking similar culinary enhancements through cutting-edge technology, we invite you to explore the possibilities with us.

For more information please visit www.dcnorris.com

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DC Norris North America now offers food producers an expanded equipment portfolio including BCH Ltd and Marel. The portfolio expansion is part of the company’s mission to provide world-renowned processing solutions, expertise, and equipment to the North American market. DC Norris North America will continue to expand its equipment portfolio as additional machinery brands prove their positive impact and value in food production.

expertise to offer the best food processing solutions

Widely known for installing innovative, turnkey industrial food processing systems for some of the most recognized food brands around the globe, DC Norris is committed to offering food manufacturers the equipment and expertise they need to build and operate highly efficient food processing operations.

That commitment drives them to develop and manufacture their own equipment portfolio and to continuously trial and incorporate other world-renowned equipment providers, too.

The incorporation of BCH into their existing portfolio will enable them to bring prepared food producers more of the best solutions and equipment the industry has to offer.  The DC Norris North America team have the expertise and breadth of knowledge to advise on the right equipment for the customers individual product and process.

New line of BCH equipment

DC Norris North America’s new line of BCH equipment includes Atmospheric, Pressure and Vacuum Cooking Systems, as well as a range of process cooling systems. The BCH Vacuum Cooling solution is the fastest, safest and most energy efficient method of cooling on the market.

Several other BCH solutions are now represented under the DC Norris North America umbrella such as Bratt Pans, the Orbiter range of electrically and steam heated tilting kettles, CIP Systems and the Optima all-in-one processing solution.  They will also offer confectionery equipment such as batch and continuous vacuum cookers and forming systems.

Stuart Grogan, Operation Director at BCH commented, “The entire team here at BCH are thrilled to be joining the DC Norris North America portfolio of internationally recognised brands. We look forward to supporting both the team and their North American customer base with our extensive process knowledge and range of solutions across the food and confectionery markets.”

This new line of BCH’s industrial food processing equipment compliments the Company’s existing portfolio of food processing systems that include industrial Sous Vide, Cook Chill and the DCN Jet Cook™.

Marel: loading, lifting & discharging equipment

DC Norris North America also proudly represents Marel and its line of loading, lifting and discharging equipment. Based on a broad range of standard loaders, the Marel portfolio made available through DC Norris North America offers industrial Euro style buggy lifting equipment and loading solutions for the food processing industry.

All Marel equipment is CE-marked and manufactured with a focus on flexibility, high quality and hygienic design.  Designed completely in stainless steel, the Marel line of lifts and loaders comply with every food safety regulation in the industry.

Dick Smith, President of DC Norris North America noted, “We’re committed to seeking new ways to make our clients’ businesses and manufacturing processes more efficient.  By expanding our portfolio, we can offer a greater breadth of expertise whilst also innovating to support an evolving customer base.”

DC Norris North America’s expanded equipment portfolio can be found on their newly designed website www.dcnorrisna.com. Through the website, information about the full range of food processing machinery is available, including instant downloads of brochures and specification sheets. Enquiries can be made through the contact form on the website or by calling (231) 935-1519.

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We are thrilled to announce that DC Norris is making its debut at the inaugural InFlavour Expo 2023 in Riyadh this October. ✨

Join us at this spectacular event as we unveil our cutting-edge DCN Jet Cook™ Technology. Our team of specialists will be on hand to discuss all your processing needs for the food, beverage, and pet food industry.

Date: 29th – 31st October, 2023
Location: Stand No # H2.S28, Riyadh Convention & Exhibition Centre
Time: 10am – 7pm (AST)

At DC Norris, we are passionate about revolutionising the way food is processed, and we can’t wait to share our proven and innovative process solutions with you, with 20+ systems already installed in Qatar, Saudi and the UAE. Whether you’re in the business of creating delicious meals, refreshing beverages, or nourishing pet food, we have the expertise to enhance your production process.

Don’t miss out on this incredible opportunity to explore our technology, gain valuable insights, and connect with industry experts. Let’s take your food processing to the next level, register now!

Stay tuned for more updates and surprises in store. See you at the InFlavour Expo 2023!

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DC Norris are thrilled to announce our participation in this year’s Gulfood Manufacturing exhibition at the World Trade Centre, Dubai on 7th – 9th November 2023. The event, renowned for showcasing the latest advancements in the food processing industry, will serve as the perfect platform for DC Norris to demonstrate its revolutionary energy-efficient systems which have been designed to reduce customers carbon footprint and production costs.

DC Norris has consistently been at the forefront of delivering innovative solutions that transform the food processing landscape. The company’s Ready-2-Cook Kettle System, featuring the cutting-edge Jet Cook Technology, represents a significant leap in efficiency and quality for the food production sector. This system is designed to streamline cooking processes, reduce production times, and enhance the overall flavour and nutritional value of prepared foods. The system is ready to start cooking with minimal installation and training required, the Kettle is available as a tilting or static version, and is ideal for cooking a wide range of food and beverage products.

In addition to the Ready-2-Cook Kettle System, DC Norris will showcase their pioneering Can Opening Solutions. These solutions are designed to optimise the can opening process, enhancing both speed and safety in food production lines. By utilising the latest technology, DC Norris aims to provide food manufacturers with a seamless and efficient method for opening various types of cans, ensuring product integrity and workplace safety.

Furthermore, the exhibition will provide an opportunity for attendees to explore DC Norris’ advanced Sous Vide Systems. These systems empower chefs and food producers to achieve unparalleled precision in cooking, resulting in consistently superior taste, texture, and nutritional value of prepared foods such as meat, poultry and fish. DC Norris’ Sous Vide Systems have set a new standard in the industry by combining innovation, reliability, and ease of use.

David Norris, Managing Director comments, “We are excited to participate in Gulfood Manufacturing and present our latest innovations to industry professionals and partners from around the world, our Kettle Systems, Jet Cook Technology, Can Opening Solutions, and Sous Vide Systems represent our commitment to revolutionising food processing methods and delivering solutions that empower our customers.”

Gulfood Manufacturing attendees are invited to visit DC Norris’ booth in the UK Pavilion, Stand S-K4 to witness these innovative systems in action and engage with DC Norris’ experts to learn more about the benefits they bring to food processing operations.

We encourage you to book a meeting with our food and beverage product and processing experts during the show, to do so please click here.

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Last month we invited customers from Africa to the DCN Product Development Kitchen at CPUT in Cape Town for advanced Jet Cook product and processing training and trials. The popularity of our Jet Cook condensed milk systems brought customers from South Africa, Democratic Republic of Congo, Nigeria and Sudan for the demonstrations on DCN’s latest technologies.

Many of these customers are currently purchasing Condensed Milk from Malaysia, Indonesia and Germany and now want to explore production of condensed milk in-house/country.  A drawback of importing the product are long lead times, currency fluctuation, increased transport costs, volumes, waste and product availability.  Most of the customers re-pack the canned product into 30gram sachets for the local market, which adds even more cost and increases the chances of food contamination.

The DCN Jet Cook process offers huge energy savings, reduced water usage and rapid processing times with a very small footprint.  Hot filling directly from our system, will increase product shelf-life, stability and ensure a food safe finished product. Our customers will have the flexibility to produce bespoke products such as flavoured condensed milk or creamer without having to commit to the large volumes that the co-packers require.

During our trial 250kg and 300kgs batches of condensed milk were produced within 18-20 minutes and had an attractive creamy mouthfeel, dairy flavour with high gloss and excellent viscosity.

We also completed advanced product and NPD training with a customer who is a leading chilled ready meals producer in South Africa, and has used DCN Jet Cook Technology for more than 10 years. The training included Jet Cook Process, Emulsions, Braising Bar and demonstrating the advantages of our Vapour Reduction System.

We also produced an extended tomato paste product and two types of vegan mayonnaise, (60% and 52% oil)  at CPUT, both to the satisfaction of the customer.

DCN will be back in Cape Town in January installing another Jet Cook System to produce sauces and ready meals, as well as completing more trials at the CPUT’s Product Development Kitchen.

If you interested in booking a trial or would like more information on DCN and our products and processes, please contact info@dcnorris.com or c.tucker@courlanders.co.za

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The rise in popularity of Oat Milk

The surge in demand for oat milk and other ‘free-from’ food and beverages in recent years has expanded the offerings on supermarket and café shelves. This expansion has been a game-changer for those adopting a dairy-free diet, with non-dairy milks such as oat, almond, coconut, and soya becoming staple alternatives. The shift toward plant-based foods has largely been driven by factors such as allergies, intolerance, the quest for healthier options, and the desire to reduce environmental footprints.

In the past, these beverages weren’t readily available off-the-shelf. However, food producers have tapped into this trend, leading to a significant demand for equipment that can manufacture these alternative products to a high standard and in large volumes.

The Challenges with Oat Milk Processing

DC Norris has spent over 50 years helping food and beverage producers innovate their equipment to meet the tastes and demands of today’s consumer. One of the biggest challenges plant-based beverage producers face is replicating the desirable attributes of animal milk, such as creaminess, texture, taste, and health benefits. With different chemical compositions – fat, protein, carbohydrate, and minerals in milk versus oil bodies in plant-based products – it’s a challenge to replicate the qualities of animal milk. This process requires additional machines, steps, and additives. To meet consumer demands, ensure safety, and deliver a high-quality product, the right machinery and operational processes are crucial.

The traditional oat milk production process is a complex, multi-stage operation that can include pre-soaking oats, heating, homogenisation, adding amylase, and a holding stage, followed by a final heating to denature the amylase before cooling and filling.

Our Jet Cook is an innovative solution to the challenges of plant-based beverage production. It reduces risk factors and ensures consistent high-quality output. Jet Cook uses a patented steam system (the Jet Nozzle) that simultaneously heats, mixes, and pumps the product earning substantial energy savings while not compromising on flavour.

Investing in Jet Cook offers oat milk manufacturers a quick return on investment with a multitude of benefits, including reduced production times of up to 50%, 45-55% energy-savings, 8-10% reduction in ingredient additions like amylase and salt, reduced cleaning times and chemical usage, and less water usage.

A Real-World Example – Jet Cook Oat Milk Production

In 2019, a world-leading ambient beverage manufacturer sought our expertise to improve their grain-based beverage production. Their objectives were to match the existing product flavour, achieve a creamier mouthfeel and smoother texture, and reduce the long processing stages and times. We ran processing trials at our Product Development Kitchens in both the UK and Cape Town South Africa prior to installation, ensuring we met their requirements. The system we proposed has the capacity to produce 15,000lt p/h, increasing their throughput and reducing energy and water usage. This resulted in a return on their initial investment within just 12 months.

Jet Cook: A Quick Return on Investment

As plant-based beverage production continues to grow, investing in our Jet Cook™ or other industry-leading cooking equipment will equip your business to produce delicious, safe, high-quality products efficiently and cost-effectively.

Now that you have a better understanding of oat milk production and the cutting-edge solutions DC Norris offers, why not take the next step?

Get in touch: Our team of experts is always ready to discuss how our solutions can meet your unique needs. Contact us today for more information.

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It is time for another ‘Meet The Team! Introducing Rachel Hughes, our Office & HR Administrator. Rachel joined the company just under 2 years ago, starting as an administrator. Rachel quickly took on more responsibilities, ‘My job has evolved since joining and I now do HR tasks as well as general Admin. This could be anything from booking travel, preparing offer letters, contracts, to dealing with Recruitment Agencies. I also get involved with Purchasing, Spares and Accounts. I like to be organised and help out where and when I can – I will always try to make things easier, I also love creating a spreadsheet for things!  The best part of the job is the people – we have a really friendly team here and I love that I can come into work and be myself’.

Rachel’s interests outside of work are house renovating and spending time with friends and family.

Rachel likes getting her nails done and has a lot of tattoos, her favourite one is her cats name on her ankle.

General Manager, Sharon Owen says, “Alongside being a very caring and thoughtful person, Rachel is the most organised person I know! Nothing is too much trouble and you can guarantee any task will be completed to the highest standard.  Rachel is a great fit for the Admin team and has a very bright future ahead of her”.

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Congratulations to Dianne March for 25 Years at DC Norris today! Dianne started in 1998 working on our reception desk, then moved into technical sales where she prepares all the quotes for our customers.

DCN’s Director, Ian Jones commented, ‘Dianne is one of our longest serving employees and is a mainstay of the Sales Team at DCN.  Her attention to detail and in-depth knowledge of DCN equipment and systems means we can turn urgent and detailed proposals around in hours instead of days when required.

Dianne is a conscientious, diligent, and loyal employee who we all love to work with, she also keeps the Sales Team in-line and ensures we offer a professional approach to proposals.’

Dianne is currently enjoying a well-earned holiday in Zante!

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