Dynatec has developed a new system that could potentially eliminate the need for using steam in tunnel ovens, allowing many bakeries to save significant amounts of energy.

– “This is an exciting new technology, and even though everything isn’t 100% finalized, we feel confident that we’ll be able to reduce energy consumption in the bakery industry,” says Vegar Pedersen at Dynatec.

Pedersen, a mechanical engineer, has been involved in developing the energy-saving system. It is based on the fact that most bakeries use steam when baking bread and other goods in tunnel ovens. Steam creates a mist at the oven’s entrance, condensing on the surface of the dough as it enters. This thin layer of moisture provides several benefits.

– “The moisture makes the surface more elastic, reducing resistance during the final rise and increasing volume. Sufficient moisture also significantly reduces the likelihood of cracks. The products achieve a more even color, and depending on how steam is applied, you can achieve varying levels of gloss and thinner crusts,” Pedersen explains.

 

Highly relevant now
The primary advantage of steam is its ability to evenly distribute water across the surface of the bread without over- or under-doing it. Too little or uneven moisture won’t achieve the same effect, while too much water can pool at the edges, causing the bread to stick to the baking surface.

– “The problem is that it takes a lot of energy to boil all this water just to distribute it evenly,” Pedersen says.

For that reason, Dynatec has long wanted to eliminate the need for steam. Pedersen explains that they attempted to introduce a solution several years ago, but there was little interest in the industry at the time.

– “With today’s electricity prices, the situation has changed. This is now very relevant, which is why we’ve developed a system that sprays uncooked water evenly over the baked goods before they enter the oven. The system has been tested at one of Norway’s largest bakery chains for several months, and the preliminary results are very promising.”

 

The system has been tested at one of Norway’s largest bakery chains for a few months, and the preliminary results are very promising.

Vegar Pedersen, Dynatec

 

Fine-tuning the details
Pedersen explains that the system uses two nozzles that precisely spray water onto the products from both sides.

– “It has been a challenge to ensure the nozzles hit the entire curvature of the bread, but we’ve achieved that. The concept is successful in moistening the bread to prevent cracking. However, we’ve struggled to achieve the same level of shine and gloss as steam. The problem is that water evaporates a bit faster than steam, leaving the surface matte. But we believe we’ve found a solution. In the last test round, we added a small amount of water to the surface in zone 3 of the oven, and this resulted in a nice gloss,” he says.

 

Potentially highly profitable
Another significant advantage of the new humidification system is the potential to lower the oven’s temperature.

– “We’ve reduced the temperature by 50 degrees in zone 1 and between 20 and 30 degrees in zones 3-4. Despite this, the products still reach the same core temperature as before. This is because 100-degree steam helps reduce the temperature in an oven that needs to maintain 200 to 300 degrees. By removing the steam, the oven requires less energy to maintain its temperature, allowing bakeries to save on electricity for both the oven and the steam boiler.”

While the developers haven’t yet concluded whether it will be possible to eliminate all steam, they are optimistic about significantly reducing its usage.

– “If we can eliminate the need for steam boilers entirely, this system will become truly profitable,” says Pedersen.

– “What is your timeline?”

– “Some testing remains, but we expect to be ready for orders by the end of the year. Our hope is that rapid adoption will contribute to significantly lower energy consumption in Norwegian bakeries.”

(Article from Baker og Konditor, issue 5 – 2022 – Text by: Hanne Maria Westeren)