Achieving operational excellence for industrial baking ovens

A series of experiments were performed on industrial baking ovens across five confectionery manufacturing sites around the world. The impact of different operating parameters such as air and fuel flowrates, oven temperature, exhaust flowrates and ambient temperature etc., on the product quality and overall oven performance were investigated. The energy flows through the baking oven were modelled using experimentally determined inputs to estimate the reduction in heat losses. A step change in operational efficiency was achieved through the study delivering 8.5% improvement in the oven performance. On average, 92 tonnes/annum of CO2 were saved from each oven. An additional 7% efficiency improvement was observed by integrating the baking oven with a heat recovery technology saving circa £16k in fuel cost annually from a single oven. The observations and learnings from the work are not limited to baking ovens only, but can also be applied to other food manufacturing processes such as frying, broiling, roasting or grilling.