A global restaurant franchise partnered with BCH to scale up production of its signature sauces. The result was a custom-built cook/cool solution that delivered high output, consistent quality and reduced operational costs, meeting demand across an international network of restaurants.

A well known, international restaurant chain with a global footprint, known for its diverse menu of freshly prepared dishes. The company needed to meet growing demand across their locations for a modernised approach to producing and transporting their range of sauces. 

The client needed to produce a variety of sauces, including mayonnaise-based dressings, spicy pastes, and marinades, at scale, without compromising on quality. The client’s existing cooking methods were high in energy and labour costs, inconsistent in flavour and texture and had long cooling and scaling times. 

They required a hygienic, high-capacity production system capable of reducing poor mixing and overcooking while improving the flavour, colour and texture of the finished product. BCH was tasked with designing a system that could handle a mixture of sauces, while producing a large enough batch that could be packaged for a number of restaurants across the world. 

All of this had to be achieved while reducing labour, energy usage and downtime.

• Increase batch size without increasing production time
• Maintain consistency across multiple sauce types
• Improve cooling efficiency to meet food safety requirements
• Automate and simplify cleaning and changeovers
• Minimise labour input whilst maximising output

BCH provided a comprehensive cook/cool solution tailored to the client’s diverse production needs:

Equipment Supplied

• 1 x 350L sauce cooking vessel (max batch 500L)
• 2  x 1000L sauce cookers
• Cookers are equipped with AE Mixer’s bottom-entry high shear mixers for flexible, efficient mixing of varied sauce textures
• 1 x 600L holding vessel for transfer and staging
• 2 x 1200L holding vessels for transfer and staging
• 2 x RotaChill Tumble Chillers (1000kg capacity) for rapid bag cooling
• Conveyor system to automate a fully automatic bag filling line

Process Overview

1. Sauces are cooked in either the 350L or 1000L vessels, depending on batch size.
2. Using vacuum transfer, hot sauces are moved from the cookers (low-risk area) to the holding vessels (high-care zone).
3. The holding vessels are linked to pipework for bag filling via:
   • BCH transfer system
   • Or an automated form-fill-seal machine (supplied by a third party)

1. Filled bags are loaded into the RotaChill tumble chiller, rapidly cooled to 5°C, and discharged for downstream handling.

Control & Automation

• 2 x PLC based cooker operating systems reporting to a remote desktop PC with a HMI screen
• Recipes can be created, edited, and monitored via BCH’s FlexiChef software
• Automated Excel batch reports for traceability
• Integrated CIP (Clean-in-Place) system for quick changeovers and hygienic production

Implementation & Commissioning

BCH managed the full system installation, commissioning and operator training:

• Installed 2x sauce cooking vessels (350L & 1000L)
• Installed 2x 1200L sauce holding vessels
• Commissioned 2x RotaChill systems
• Integrated filler, clipper and loading conveyor
• Provided control system setup and operator training

• Multiple product types: Handle an array of sauce types with fast recipe switching
• Highly efficient: Produces up to 1500 litres of a single sauce in one hour
• Rapid Heating: Water heated to target temperature in just 13 minutes
• Reduced downtime: Automated CIP functionality for easy cleaning and minimal downtime
• Consistent quality: Maintain high product consistency with no burn-on or separation
• Reduced costs: labour and energy savings through automation and faster throughput
• Fast cooling: Cooling to 5°C using RotaChill tumble chillers, enabling safe handling and storage

BCH delivered a flexible, efficient production system tailored to the needs of this global food brand to upscale its sauce production without compromising on quality or safety. The solution enabled large-scale sauce manufacturing with better quality, faster production and lower operational costs. With enhanced efficiency and reduced overheads, the company is now better positioned to scale sauce manufacturing across other regional hubs, supporting global growth with consistent, high-quality sauces.