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Biscuit Baking Technology

PUBLISHED BY ACADEMIC PRESS 2016 An imprint of Elsevier

DESCRIPTION

Biscuit Baking Technology, Second Edition, is a reference book for senior managers and staff involved in industrial scale biscuit baking. It covers the biscuit industry process, ingredients, formulations, besides design, manufacture, installation, operation and maintenance of the baking ovens.

Written by an expert on the biscuit baking industry, the book is a complete manual guide that will help engineering, production and purchasing managers and staff in the biscuit industry to make the best decisions on oven efficiency purchasing.

CONTENTS

  1. The Biscuits
  2. Baking process
  3. Biscuit design and output
  4. Heat transfer
  5. Oven designs
  6. Oven specifications: hybrid ovens
  7. Oven construction: Direct Gas Fired Ovens
  8. Oven construction: Indirect Fired Ovens
  9. Heat Recovery System
  10. Oven conveyor bands
  11. Oven conveyor design
  12. Process control systems
  13. Oven safety monitoring and alarm
  14. Oven operation: Direct Gas Fired Oven
  15. Oven operation: Indirect radiant Oven
  16. Oven efficiency
  17. Oven inspection and audit

APPENDICES

  1. Ingredients for biscuits
  2. Maintenance
  3. Combustion data
  4. Oven manufacturers
  5. Oven band manufacturers

 

 

 

For more information contact Baker Pacific at bakerman@bakerpacific.com.hk

 

Biscuit Baking Technology, 2nd Edition

Biscuit process and engineering manual – now available for Pre-Order at www.store.elsevier.com/9780128042113

For author’s 30% discount use code: ATR30

Cover 281015

 

 

Author: Iain Davidson

Expected release: 01 February 2016

Imprint: Academic Press

Print book ISBN: 9780128042113

Pages: 384

Dimensions: 229 x 152

Print Book: GBP 106.25

Paperback: GBP 125.00

 

 

 

 

 

A manual for designers and operators on the biscuit oven – baking technology

Table of Contents

INTRODUCTION

1 THE BISCUITS

2 BAKING PROCESS

3 BISCUIT DESIGN AND OUTPUT

4 HEAT TRANSFER

5 OVEN DESIGNS

6 OVEN SPECIFICATIONS: hybrid ovens

7-1 CONSTRUCTION: Direct Gas Fired Ovens

7-2 OVEN CONSTRUCTION: Indirect Fired Ovens

7-3 HEAT RECOVERY SYSTEM

8 OVEN CONVEYOR BANDS

9 OVEN CONVEYOR DESIGN

10 PROCESS CONTROL SYSTEMS

11 OVEN SAFETY MONITORING AND ALARM

12-1 OVEN OPERATION: Direct Gas Fired Oven

12-2 OVEN OPERATION: Indirect radiant Oven

13 OVEN EFFICIENCY

14 OVEN INSPECTION AND AUDIT

APPENDIX 1 Ingredients for biscuits

APPENDIX 2 Oven maintenance

APPENDIX 3 Oven manufacturers

APPENDIX 4 Oven band manufacturers

Pre-order at  www.store.elsevier.com/9780128042113 

For 30% author’s discount use code: ATR30

 

Baker Pacific Ltd. 3905 Two Exchange Square, 8 Connaught Place, Hong Kong

Tel. +852 2522 1114       email: bakerman@dircon.co.uk      

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Baking Process and Engineering Manual

A technical manual for senior technicians in the biscuit industry

 

282 pages including over 200 illustrations. Published in hard copy and e copy by Baker Pacific Ltd.

Engineering

  • Baking oven design and manufacture
  • Management of engineering and maintenance
  • Oven up-grades
  • Introduction of heat recovery system
  • Making and procuring spare parts

Production

  • Improved operation and maintenance
  • Oven efficiencies / reduced production cost
  •  Improved reliability / less downtime

Purchasing

  • Smart buying: oven designs, specifications, controls
  • Contracts: performance guarantees
  • Purchasing of spare parts and  components
  • Directory of  suppliers, including Asian manufacturers

A comprehensive manual that supports the principal activities of

purchasing, production and engineering, providing the basis for training

programs for all levels of management and staff

CONTENTS                                      Pic 1

1  The Biscuits

2  Baking Process

3  Biscuit Design and Output

4  Heat transfer

5  Oven designs

6 Oven specifications: hybrid ovens

7.1 Oven construction: Direct Gas Fired Ovens

7.2 Oven construction: Indirect Fired Ovens     Pic 2

8  Oven conveyor bands                      

9  Oven conveyor design

10 Oven control systems

11.1 Oven operation: Direct Gas Fired Oven

11.2 Oven operation: Indirect radiant Oven

12 Oven maintenance

13 Oven inspection and audit

14 Oven efficiency

APPENDIX 1: Combustion data

APPENDIX 2: Oven manufacturers

APPENDIX 3: Oven band manufacturers

APPENDIX 4: Key components

 

 

 

 

 

 baking by infrared

 

To order for the special price of USD 199.00 please request at our contact page

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Heat Recovery System

The Heat Recovery System (HRS) uses the waste heat from the burner flues. This may be used to heat one or two final zones of the oven. These zones would not require burners, giving a saving in capital and running costs.

All gas burners draw in a large amount of air for combustion. 1.0m3 of gas requires 3.0m3 of oxygen, (approximately 15m3 of air) for complete combustion. This air is exhausted through the extraction system of a direct gas fired oven and through the natural draught burner flue of an indirect oven. The hot air and burnt gas in the burner flues of an Indirect Radiant oven are at a high temperature, typically up to 200oC in the first zones and this hot air can be recovered and used for baking in a Heat Recovery System.

A proportion of the hot gases in the burner flues are diverted to an HRS collection pipe which runs along the top of the oven. Hot gases are collected from each zone with a burner. The hot gases are drawn along the collection pipe by a fan and blown into radiant ducts in the final oven zone.

 

HRS oven 2

 

The HRS zone is constructed with radiant ducts above and below the oven band. The hot gases recovered from the burner flues are fed by the fan to the ducts. The fan is located on top of the oven at the end of the collection pipe.

Oven efficiency with Heat Recovery System

Independent tests were carried out on 3 ovens in the same factory producing identical rotary moulded biscuits with the same baking time. The tests measured the oven efficiency by calculating the energy usage (gas) in kWh (kilowatt hours) to produce one kilo of baked biscuit.

 

Oven efficiency table

 

The Baker Pacific Indirect Radiant oven was 18% more efficient than the DGF/cyclotherm oven and 6% more efficient than the DGF/convection oven. The savings in gas consumption per 8 hour shift (23 tonnes of biscuits) are approximately 212 m3 of gas compared to the DGF/cyclo and 62 m3 compared to the DGF/convection ovens.

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Heat Recovery System

The Heat Recovery System (HRS) uses the waste heat from the burner flues. This may be used to heat one or two final zones of the oven. These zones would not require burners, giving a saving in capital and running costs.

A proportion of the hot gases in the burner flues are diverted to an HRS collection pipe which runs along the top of the oven. Hot gases are collected from each zone with a burner. The hot gases are drawn along the collection pipe by a fan and blown into radiant ducts in the final oven zone.

Heat recovery main pic

Baker Pacific Indirect Radiant Oven with Heat Recovery System

 

 The burner flue is connected to the HRS collection pipe and the flow of hot gases is controlled by dampers.   One damper controls the exhaust flue and one damper controls the connecting pipe from the burner flue to the collection pipe. These dampers are set by the commissioning engineer to allow sufficient quantity of heat for the final zone(s) of the oven.

The HRS zone is constructed with radiant ducts above and below the oven band. The hot gases recovered from the burner flues are fed by the fan to the ducts. The fan is located on top of the oven at the end of the collection pipe.

The Heat Recovery System saves capital and running costs. By using recovered heat from the system shown, the fuel cost was reduced by 15%.

Details of the design and construction of the Heat Recovery System, with airflow calculations are included in the Baking Process and Engineering Manual available from Baker Pacific. For further details, please request at our Contacts page.

 

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