Save the environment or save money? Many operators have long felt that they had to choose either one or the other because the premium prices on most eco-friendly equipment often conflicted with the never-ending need to keep costs down. Add to that the constantly lengthening laundry list of local, state and federal environmental regulations (and the fines for breaking them) and the dilemma becomes even more daunting.

Fortunately, a number of manufacturers are developing equipment and systems that can help operators keep their green standards up and their costs down. When considering an equipment upgrade or replacement, Alan Crosley, marketing manager for Hicksville, N.Y.-based, Empire Baking Equipment, suggests that customers take some time to do a simple cost analysis of their entire operation to identify potential inefficiencies that can be remedied with the appropriate equipment solutions.

“In most cases, we’re able to show the customer that the energy savings are greater than the lease payments themselves, allowing them to actually return money to their bottom line, or use this return to invest in other cost-saving areas,” says Crosley.

When it comes to energy-guzzlers, inefficient ovens can really break the bank. Along with higher fuel costs, inconsistent bakes also can waste large amounts of money in time, labor and ingredients.

Whether you’re firing with electricity, gas or oil, the oven accounts for 50 percent to 70 percent of your energy consumption and at least 27 percent of your energy costs, according to a report from WP Bakery Group, parent

company of Shelton, Conn.-based Kemper Bakery Systems. Kemper vice president of industrial sales, Jim Souza, explains that “just like in your home, good insulation is the key to energy savings.” Also make sure the burner control is sophisticated enough to ensure an even flow of energy while minimizing waste.

Innovative interior construction enables one Empire deck oven model to save a minimum of 60 percent in fuel consumption over an old-style revolving bread oven. A burner chamber and firebox constructed from oven brick and a wall and roof vapor tube system encased in poured cement enables this model to sustain even, brick-oven-caliber, radiant heat when the burner shuts down, says Crosley. The oven has no boiler or moving parts, which hold “maintenance and downtime to a bare minimum,” he says.

One of the easiest, most effective ways to increase energy efficiency all too often goes “untapped or under-utilized,” says Doug Kozenski, sales manager for Heat and Control, Inc. in Hayward, Calif.

“Fryers and ovens, for example, produce millions of BTUs of heat, some of which is vented into the atmosphere, a vast supply of potential energy that is simply wasted,” he says.

Heat and Control designs equipment and systems to capture that heat for productive reuse to improve the combustion efficiency of cooking oil heat exchangers, heat cooking oil or water for sanitation or building temperature control, he explains.

“The result is a solution that also reduces the environmental impact of fryers and ovens and protect air quality,” says Kozenski.

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SAVE ON FUEL

Vapor Tube Deck Ovens feature advanced vapor tube technology that facilitates heat distribution and retention. Vapor Tubes deliver heat evenly throughout the product zone, with no fans or moving parts necessary to distribute the heat. This provides consistent quality from front-to-back, side-to-side and deck-to-deck with no damper or airflow adjustments. Each deck has its own self-contained steam generator, so a steam boiler is not needed, saving on fuel, space and maintenance.

Empire Bakery Equipment
800 878 4070
www.empirebake.com

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DESIGNED TO REQUIRE LESS POWER

The low-tension spiral coolers from AMF Bakery Systems are designed for high operating efficiency at minimum power requirements. The spiral cooling tower entry/exit configuration options permit the most efficient use of available plant space. The heavy-duty construction consists of quality materials and components, assuring high performance, minimum maintenance and longevity. A modular cage main drive, take-up, infeed conveyor and discharge conveyor allow for fast installation and start-up.

AMF Bakery Systems
800 225 3771
www.amfbakery.com

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INCREASE FREEZER EFFICIENCY

The G & F Systems’ “G” series increases blast freezer efficiency as well as line efficiency. The system eliminates the need to interrupt production to shut down for defrosting. The simple and straightforward design doesn’t require complicated, difficult to clean baffles or complex, expensive refrigeration piping. Designed for a 24/5 schedule, the “G” series system is ideal for demanding plant requirements.

G & F Systems
516 868 4923
www.gfsystems.com

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FIGHT AIR POLUTION

As it heats cooking oil, Heat and Control’s high-efficiency KleenHeat pollution control heat exchanger incinerates and removes oil, odors, and other particulates from fryer stack exhaust that would otherwise pollute the air and area around your plant. Without using additional fuel, KleenHeat’s thermal efficiency exceeds that of heat exchangers that do not offer pollution control. KleenHeat’s all-welded stainless steel tube bundles are maintenance free.

Heat and Control
800 227 5980
www.heatandcontrol.com

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GREEN DESIGN

The Henry Group’s indirect gas-fired Turbo Therm tunnel oven is extremely versatile and energy efficient. The design of the air turbulence system in the bake chamber allows the oven to operate at lower temperatures and provide faster bake times. An integrated catalytic oxidizer uses the latent heat energy of the ethanol oxidation process to improve baking efficiency for a typical reduction of 13 percent to 20 percent of fuel consumption.

The Henry Group
800 356 7591
www.thehenrygroup.com

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USE LESS ENERGY

The Matador multi-deck baking oven is suitable for baking bread, tin loaves, rolls and fine pastry. Its gas flow is controlled via the Zyklotherm heating system, which ensures absolute even heat distribution, even in the front of the oven. A dimensionally stable heat register allows baking at maximum temperatures in order to produce strong-crust products. WP Matador offers energy saving technology–up to a 30 percent savings compared to similar oven types. Standard features include stone baking plates, stainless steel baking chamber doors and the Navigo control system.

Kemper Bakery Systems
subsidiary of WP Bakery Group
203 929 6530
www.wpbakerygroupusa.com