Sustainability efforts comprise numerous aspects, with opportunities for improvements big and small in many nooks and especially crannies, which all add up. Steel belts for baking ovens are able to provide some of the most visible efficiency results in this regard. IPCO shows how that’s done.
Baking ovens can account for as much as 45% of a bakery’s overall energy consumption; of this, as much of 25% is used to heat the conveyor belt, which is why maximum efficiency is not only recommended but necessary, as it can have a major impact on overall energy costs. Moreover, “Solid steel belts are inherently lighter than mesh belts – perforated belts even more so – and this translates into significant advantages in terms of energy efficiency,” Marko Leber (Global Product manager, Food – IPCO) highlighted this for us, pointing out two main reasons: a lighter belt means less steel to reheat with up to 30% less energy required. Lower weight also means less power is needed to ‘drive’ the belt through the oven.
Energy efficiency is becoming increasingly important for the industry. “The new oven technologies coupled with our high-quality steel belts enable such efficient energy recovery,” explains Thorleif Brokke, director sales, Berndorf Band Group. To maximize efficiency, the Austrian company recommends periodic inspections of the steel belt and belt system to keep everything clean and replacing parts that wear such as scrapers, brushes, supporting elements, etc. “Furthermore, preventive cleaning is always advisable, to avoid heavy pollution of the belt and to save costs and time,” Brokke suggests.
And that’s not all; as a conveying medium that’s completely flat and smooth, a steel belt has the major advantage of having no gaps, recesses, or crevices in which carbon deposits could collect. This makes them inherently quicker and easier to clean than mesh belts. “As well as minimizing the risk of harmful acrylamide build-up, the ‘cleanability’ of a flat belt means less water consumption, reduced use of chemicals/detergents, and – depending on the cleaning method – less energy expended on heat,” Leber explains.
Hot and cold
Steel bake oven belts maintain their properties over years of operation through thermal stresses of constant cooling and re-heating to temperatures as high as 400°C. Issues anywhere in the system can have an impact on how straight and flat the belt is. “For instance, wavy belt edges can be a sign of uneven temperature in the oven, or an indication of side wandering caused by dirty, worn, or ill-adjusted drums, idlers, skid bars or break points. Edge burrs are a sign of the belt coming into contact with the structure of the conveyor, a clear sign that something in the system is not operating as it should,” explains Leber (IPCO). In case the steel belt does suffer damage, it can usually be repaired fairly easily, extending its working life and adding to its credentials in terms of sustainability. If there is a problem with the belt edge and the root cause is identified and rectified, the belt can be trimmed if necessary and then filed to a round finish. If there’s a crack at the belt edge, a crescent-shaped piece can be cut out and the edges filed so that they are round. If the crack is within the belt, small holes can be drilled at each end of the crack to prevent it from spreading. And if more serious damage occurs, the damaged area can be cut out completely and a new piece spliced in.
To extend the lifespan of the steel belt, tracking problems should be consistently monitored and corrected as soon as possible. Belt tracking systems from the Berndorf Band Group are therefore recommended from the start of the implementation of the steel belt. “After the machine has been given a thorough inspection by one of our experts, we will compose the most suitable system and install it within a few weeks. Our experts can also advise customers on their existing systems,” Brokke (Berndorf Band Group) details.
IPCO steel belts
IPCO can produce solid and perforated steel bake oven belts to virtually any length and in widths from 800mm to 3,500mm. The company has a global sales and service operation with offices in more than 30 countries. This local presence is supported by a global engineering team, enabling IPCO to provide oven builders and end-users with technical advice, system solutions based on a comprehensive range of conveyor components, and a responsive repair/maintenance support service designed to maximize oven uptime.
