Climate profiling


Introduction

This problem is well known to all industrial producers of baked goods:

How to find the optimal settings for baking- and proofer-lines.

If you have a brand new line, master bakers of your supplier will adjust your new line in cooperation with your own staff. At your long-term running lines, normally your line-supervisors have the experience to do the right setting for the different types of products there.

Nevertheless sometimes the product quality is inadequate and not in wanted quality range.

In often cases this will cause heated discussions between bakers and dough makers, but without finding the reasons for this troubles.

Often producers and suppliers fight hard together to name each other as responsible for the troubles in production, especially when the bills are not paid.

Solutions for all these problems are climate profile measurements in the relevant lines,
performed by 3S Sensor & Service Schmidt GmbH.

We have an experience for more than 25 years in this business while we have inspected much more than 350 lines worldwide.

Our service is neutral and absolutely independent from the well know suppliers of bakery equipment.
It is obvious, that all results of our investigations are strictly confidential.


Typical profiles for durable baked Products.


 

Execution of climate profile measuring.

Our patented PHTM-measuring system consists of an isolating box as well as the humidity and temperature sensors.

The first step is to evaluate whether the insulating box has sufficient clearance in the proofer respective the oven to ensure a trough passing without any problems.

It depends on the kind of product which isolating box is used:


A flat box, with a height of approx. 60 mm is used for durable baked good like hard biscuits and similar products with baking times of < 30 min. and baking room temperatures of about 225 °C.


Bread, cakes, and pastries with baking times of up to 120 min and baking chamber temperatures up to 275 °C require appropriately more strongly isolated and thus higher boxes.

Protected for heat immersion, the insulating box contains:
The data logger, the power supply, the amplifiers for the sensors, and when required, special frozen cooling elements.

Up to 3 composite humidity and temperature sensors, fitted in special designed holders with magnets, can be arranged on the conveyor at any wanted positions.

We don’t use sensor bars to avoid collisions in the baking chamber, which can lead to disastrous damages.

After the logger is programmed and the sensors are heated up, the measuring system can be put on the conveyor. With the sensors ahead, the unit runs through the oven among the product.

The respective humidity- and temperature values are measured and recorded permanently at the measuring places. After leaving the oven the logger will be read out. The graphically depicted profile will be available immediately.
If necessary, the unit, equipped with new cooling elements, is instantly ready for the next run. 

 

 

 

 

Profil in a cracker oven before optimisation

 

 

Optimisation of oven settings.

The climate profiles will immediately show and rectify any deviations from the set point profile.

A comparison with earlier measurements is possible without problems.
Optimal settings found at once can be documented and archived so.


An other advantage of this measuring method is that profiles of different lines can be compared with each other. This way, the profiles of optimally operated lines can be transferred to lines with insufficient product quality.


It has proved to be very helpful, to do measurements in old lines before their demolition. Their profile can be adapted easily to the new and often more powerful lines. This could be very often shortened the start up drastically.

 

At lines with insufficient product quality, at first the actual state is determined with the first measurement. At this stage it can be decided, whether wrong settings are the cause or technical faults.

In this case, the line manufacturer is able to carry out a repair due to the findings of the profile measurement.
 

At faulty settings, they have to change the settings so often till the desired success is reached.
It is obvious that after every change further measurements are necessary to check the influence and the effectiveness respectively.


During this procedure all changes must be documented with the respective measurement results.
At later problems the cause can be found easily with this archived documentation of further measurements.
     

 

 

 

 

Profile in a Cracker oven after optimisation