One tunnel oven can different heat transfer methods — radiant, convection or conduction — in different sequences to optimize the baking profile. Source: Topos Mondial
Hybrid ovens may let bakers mix and match heat transfer methods to get the exact baking curve, but careful setup ensures no time or energy is wasted as products move through the oven.
“Getting the best out of any oven involves optimizing the process for product quality, bake time and fuel efficiency,” Mr. Graham said. “There are many combinations of process parameters that will result in an acceptable product, but the wrong combination may restrict output or lead to higher-than-necessary fuel consumption.”
Knowing how each product develops in the oven can also give bakers helpful insight in how to get the most from their hybrid oven. RBS’s Scorpion data logger maps the environment of the oven and quantifies convection speeds, temperatures, humidity and other parameters.
“Once the baking process is benchmarked, the oven designer can apply the most efficient zone to the process,” Mr. Kuipers said.
Once that’s determined, PLCs maintain that level of quality control by allowing operators control over burners, dampers and airflow.
“That’s where you can maximize control of the temperature ranges for different types of products,” Mr. Fischer said.
Mr. Breeswine said modular ovens can give bakers control over each section, as in the case of modular multideck ovens.
“These ovens allow the independent regulation of baking decks, thus product-specific regulation of baking parameters,” he said. This ability to control the parameters of each deck allows bakers to bake a wide range of products.
J4’s cyclothermic oven modules are equipped with duotherms, which use fans to blow baking chamber air onto the products.
“Duotherms can blow the air either from the top or from the bottom, resulting in convective heat transfer that is intensified on-demand,” Dr. Nikel explained.
To make them even more customizable, J4 developed duotherms that can control air turbulence on top and bottom independently in a single module.
Getting the best performance out of an oven doesn’t necessarily need to involve the latest technology.
“Some of the best practices for any oven is to keep it well maintained and full during production,” Mr. Kauffman said. “The skips or gaps in production from dwells or changeovers or running an underutilized oven results in inefficient energy use and non-uniform baking before and after a break in production.”
Keeping ovens maintained is also key in keeping things running smoothly. AMF’s Guardian Chain Management System extends chain life by ensuring it is well-maintained. That includes maintenance analysis, automated chain tensioning, side-to-side equilibrium control and predictive lubrication alarms.
Choosing the right baking surface is also critical to optimize baking performance, particularly in ovens that use conductive heat. Oven bands can direct the heat in a conductive situation and impact airflow in a convection oven.
“We offer a variety of product-carrying surfaces from tight mesh belts for baking directly on the hearth to more robust grid construction for heavy Pullman pans with lids, all in addition to steel bands, steel plates and stone hearths,” Mr. Kauffman said.
With a modular and/or hybrid oven, bakers can get a tailored bake for a wide product portfolio. Hybrid ovens let bakers tinker with just the right amount of various heat transfer methods to find the perfect bake. Modules help customize length and burner numbers to get just the right fit. All of this leads to a custom bake and more flexible production.
