Hollow Road Provisions
SOP-014Two-Stage Cooling of Cooked Product
Purpose
Cooked product that will be held overnight has to pass through the temperature range where bacteria multiply fastest — and it has to pass through fast enough that they don't. This procedure tells you how to do that, how to check that it worked, and what to do when it didn't.
When to use this
Any batch of cooked product — sauces, chutneys, cooked fillings — that will not be hot-filled and sealed within 30 minutes of coming off heat.
What you need
- Calibrated probe thermometer
- Frozen ice wands, from the chest freezer — enough for one per pan, plus extras for corrective cooling
- Shallow 2-inch pans — not the deep tubs
- Cooling log, on the clipboard at the walk-in door
The two limits that matter
Critical limits — both must be met
Missing Stage 1 cannot be fixed by Stage 2. If the 90-minute check reads above 70°F, go to Step 8 immediately.
Procedure
- Write down the time the batch comes off heat, on the log, before you do anything else. This is your Stage 1 start time. Every limit below counts from this number.
- Transfer the product into shallow pans, filling no deeper than 2 inches. Deep tubs cool from the outside in and will not make the window, no matter how cold the walk-in is.
- Put one ice wand in each pan. Do not stack pans on top of each other.
- Move the pans to the walk-in, on the wire rack nearest the door. Leave two inches between pans so air can move.
- Probe the center of one pan at 30 minutes. Record the temperature and the time.
- Probe again at 90 minutes. Record it.
- 70°F or below — Stage 1 passed. Go to Step 7.
- Above 70°F — go to Step 8 now. Do not wait for the 2-hour mark.
- Stir each pan and re-probe at least every 2 hours. Take the final reading no later than 6 hours after the Stage 1 start time you wrote down in Step 1.
- 41°F or below — cover the pans, label them with the product name and the date the batch came off heat, and move them to the back rack.
- Still above 41°F at 6 hours — go to Step 9.
- If Stage 1 is at risk
Use this only when the 2-hour limit has not yet been reached. Once it has, corrective cooling will not bring the batch back into compliance.
- Split the batch across more pans, half as deep.
- Add a second ice wand to each pan.
- Re-probe at 15 minutes, then every 15 minutes until the 2-hour limit.
- If the center is still above 70°F when the 2-hour limit is reached, stop. Do not keep cooling it for overnight hold. Go to Step 9.
- Cooling failure — either limit missed
- Do not move the batch to the back rack.
- Tag the pans DO NOT USE.
- Write “Cooling fail” on the log with the time and which limit was missed.
- Tell the Production Lead before you leave for the night.
Do not leave this decision for the morning shift. They have no way to know how long it sat.
Records
The cooling log stays on the walk-in door clipboard for the current week, then goes in the binder in the office. Record readings as you take them. Do not fill in times you did not observe.
Revision history
| Rev | Date | Change | By |
|---|---|---|---|
| 3 | 06 Mar 2026 | Added the Step 8 branch after the February batch loss. Changed deep tubs to shallow pans throughout. | Prod. Lead |
| 2 | 14 Aug 2025 | Added 90-minute check so a failing batch is caught before the 2-hour deadline. | Prod. Lead |
| 1 | 02 Feb 2025 | Initial release. | Prod. Lead |