NEWS
Baron Foodtech’s energy analysis brings energy savings to bakeries
Moilas Oy, a pioneer in gluten-free baking in Finland, was looking for sustainable, energy-saving solutions for its production instead of short-sighted applications. Baron Foodtech, an international expert in the bakery business, helped identify the bakery operations causing energy waste with the help of its new measurement system. Once deviations are found and fixed, the energy consumption of bakery equipment can be cut by up to a third.
In bakeries proofing, baking and freezing are significantly energy-consuming processes. Defects and wear in, for example, oven bulbs or door seals cause constant energy loss.
– Often, external consultants may suggest solar panels or heat recovery to improve the bakery’s energy efficiency. However, it is secondary until we find out why so much energy is consumed and what causes the possible energy waste. Refurbishing bakery equipment has a huge potential to save energy, says Matias Lehtinen, Head of Sales at Baron Foodtech, a company specializing in bakery business development. Lehtinen adds that by renovating the oven, up to 30 percent savings in gas consumption can be achieved.
An even-temperature oven gives consistent quality
The bakery Moilas Oy located in Pieksämäki, Finland, is a pioneer in gluten-free baking.
– The development of gluten-free products began in 1985, and in 1997 a separate, gluten-free bakery in Hietatie was established. In 2019, we started manufacturing only gluten-free products, CEO Ville Moilanen tells about the growth of the company founded in 1955. Today there are two bakeries, and about half of Moilas Oy’s turnover of 17 million euros comes from exports.
The family businesses Baron Foodtech and Moilas Oy have cooperated in the development of bakery production for decades. Moilas Oy was therefore a natural partner for the pilot project of measuring bakery equipment and processes.
The SCORPION 2® measurement and analysis tool used by Baron Foodtech collects data with sensors traveling through the process, for example in the oven, with the product. They measure temperature, radiant heat, air velocity, heat flux, and humidity levels in the bakery’s key processes.
The profile obtained by the measurement shows where possible energy loss or deviation occur in the measured process, which could be baking, for example. Baron Foodtech’s strong experience in the bakery business ensures that corrective measures for deviations shown by the analysis are taken thoroughly and quickly.
– If, for example, different temperatures are measured from different sides of the tunnel oven, something is wrong, Lehtinen demonstrates. – Some of the burners may not be functioning, and without automation, no separate notification occurs. Other burners compensate for the missing temperature, causing the bread to burn under the burner and creating wastage.
The heat map drawn by the sensors tells you where the spots that are too cold or hot are located. From the map, you can determine where the faulty burners are. The mechanical engineer of the team makes observations about the mechanical, electrical, and software status of the oven or other equipment and can order new parts for the machine based on the information.
Moilanen emphasizes that an oven of even temperature produces products of consistent quality. Wastage is reduced and energy is saved.
– When you must run the burners at higher power, it also affects their service life and energy consumption.
The follow-up plan offered by Baron Foodtech ensures that product quality and energy consumption remain at the optimal, desired level in the future as well.
Modernization increases the lifespan of vintage ovens
Many bakeries may still be using ovens from the 70s.
– The structure of ovens has not changed, but automation has increased. An old oven can be made functional by modernizing it, says Lehtinen.
The investment for a new oven ranges from around 500,000 euros upwards. At the same time, the bakery must consider either a break in production due to dismantling the old oven or a new space for a new oven. With the help of measurements, bakery equipment can be refurbished efficiently, improving operational reliability and product quality. With a reasonable investment, the service life can be extended by up to 15 years. When the modernization work is planned and prepared well, the changes can practically take place over a weekend.
– The measurement of the equipment can be done during normal production, meaning that the operation of the bakery does not need to be interrupted, Lehtinen adds.
As a result of the measurement, Moilas Oy has received suggestions for how to increase the energy efficiency of production, and Ville Moilanen is satisfied.
– It is easier and more reasonable to study the operation of the ovens before we make major changes. We are constantly moving towards more carbon-neutral ways of working, and energy consumption plays a significant role in that. These are important ingredients for success, he states.
Begin optimizing your bakery and conserving energy today, with Baron Foodtech!
You can make quick improvements with us,
because our tools have already made massive improvements to our clients energy efficiency.
Contact our Head of Sales, Matias Lehtinen!
Bakery in the article:
Moilas Oy