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1 Oven Product / Profiling Application and Advantages BAKINGTECH 2016 Philip Domenicucci March 1, 2016 Technology Profiling Data Oven Environment Oven Profile Examples s Profiling Data 2D Graphs: Real Time Conditions Inside the Oven at Product Level 2D Contour Maps Side to Side Oven Variations 3D Wire Mesh: Differences in Range and Amplitude of Oven Conditions S Curves (Baking Profile) Heat Flux Technology Improve Quality Control Product Optimization Validate Process Control Equipment Performance Start Ups Reporting and Monitoring Validating Kill Steps Oven Environment Lateral Temperature / Air Flow High, Low, and Average Ranges Above / Below Product Pan / Hearth Surface Temperature Absolute Humidity Heat Flux S Curves (Baking Profile) The Total Heat that the Product Encounters 1

2 Oven / Product Profiling Profile Report Including Temperature / Air Flow Graph Probe Names Zones and Set Point Temps. Time, Distance, % Travel Oven Specifications Temperature 2D Lateral Heat across the Product Path Range 0º - 600º F Temperature 2D Contour Lateral Heat Map across the Product Path Range 0º - 600º F Temperature 3D Mesh Lateral Heat Map Across the Product Path Range 0º - 600º F Air Velocity 2D Air Velocity Map Lateral Heat Flow Across the Oven Range ft.../min 9 Probes Across Oven Air Velocity 2D Contour Air Velocity Map Lateral Heat Flow Across the Oven Range ft.../min 9 Probes Across Oven 2

3 Air Velocity 3D Mesh Air Velocity Map Lateral Heat Flow Across the Oven Range ft./min 9 Probes Across Oven Product Profiling S Curve - Baking Curve 2D representations of Real Time development of:» Baking Profile» Temperature above, below and pan surface» Air Flow and Humidity Quality Control Verification SPC Analysis of Data Kill Step Varifcation Product Profiling S Curve Baking Curve Air Velocity ft. / min Temperature above and below the Pan Product Profiling Absolute Humidity (Humidity Mass Ratio) Range 0º - 550º F lbs. water / lbs. dry air Develop a Relationship Between Oven Moisture and Finished Product Moisture Product Profiling SPC Analysis Data of Profiles Producing Good Product Multiple Copies of the Profiles for an Average Good Profile Average Good Profile Process Out of Control Product Profiling Heat Flux Heat Flux Radiant vs Convective Heat Total Heat Heat Flux Graph: Radiant Heat Curve Convection Heat Curve Total Heat Flux Curve Range Btu/hr. ft.² (W/m²) Heat Flux Component Curve: Total Convective Heat 79% Total Radiant Heat 21% Units: Btu s/hr. ft.² (W/m²) 3

4 Temperature / Air Flow Probes Arrays 12 to 144 Long Up to 9 Probes K Thermocouple and Hot Wire Air Flow Sensor Outputs 2D and 3D Results of Lateral Baking Conditions Heat Flux Sensor Measures Convective and Radiant Heat Experienced by the Product Black Sensor measures sum of convective and radiant heat Gold Sensor measures the convective heat component Humidity Sensor High Temperature Moisture Sensor Low Temperature Moisture Sensor Bulk Air / Dry Bulb Sensor Kill Step Validation Identify Lateral Temperature and Air Flow Issues and correct them. Identify Heat Source for Uniform Production Lines Maintain Uniform Product Moisture Content. Monitor Oven Life Cycle Changes Kill Step Validation Lateral Heat Profiles Lateral 2D Contour Heat Map Range 0º - 650º D Set Points: 1-400ºF Range 0º - 650º D Set Points: 6-360º - 480º 4

5 3D Mesh Graph Lateral Heat Profiles Lateral Air Flow Profiles Baking Time 8.5 min Set Points: 1-400ºF Baking Time 8.5 min Baking Time 7.5 min Baking Time 7.5 min Set Points: 6-360º - 480º Lateral 2D Contour Air Flow Profiles Baking Time 8.5 min Baking Time 7.5 min FSMA Implimentation 2016 Kill Step Validation Isolate Coolest Oven Sector Measure Product Core Temps from the Sector Download Data Points Plug Sorted Data Points into Kill Process Calculator Read Process Lethality Analysis 2D Contour of Lateral Heat Variations 3D Mesh of Lateral Air Velocity 3D Mesh of New djustments 2D Heat Flux in Multiple Ovens Analysis Cold Temperature Band towards right Center of the pan. -35º F 2D Contour Temperature Profile High Air Flow Band towards right Center of the pan ft.../min 2D Contour Air Flow Profile 5

6 Analysis Lateral 3D Mesh Air Flow Profiles Oven/ Product Profiling Analysis New Tunnel Oven at Start Up Air Flow Balance Air Flow Range fpm Air Flow: 61% fpm 5% fpm Air Flow Range fpm Air Flow: 86% = FPM < 1% fpm 3D Mesh Air Flow Profile New Tunnel Oven at Start Up ft... /min. at 90% 3D Mesh Air Flow Profile New Tunnel fter Adjusting Convection flow ft... /min. at 98% Analysis Heat Flux in Multiple Ovens Differences» Bake Time» Moisture» Product Quality Conclusion: Advantage of Profiling Detailed Information on Baking Conditions» Temperatures, Air Flows, Humidity, Heat Flux» Informed Decisions for Adjustment Confirm Product Results with Oven Conditions» Dry, Over Baked, Moisture Content» S Curve Problems» Moisture Content SPC Benchmarks Kill Step Validation Application and Benefits BAKINGTECH 2016 Philip Domenicucci March 1, 2016 The End Profiling Data Delivers: Record of Oven and Product Conditions During the Product Baking Cycle Real Time Data Collection Ability to Interpret Conditions and the Impact on the Product Quality 6

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