The Emithermic® XE technology was developed to deliver consistent, even radiant heat while maximizing thermal energy retention and overall efficiency. By eliminating all Direct Gas Fired (DGF) ribbon burners, the oven developed by Reading Bakery Systems (RBS) represents a major
transformation in cracker baking.
For well over a hundred years, snack food manufacturers have been baking biscuits and crackers in direct gas-fired (DGF) tunnel ovens. But, with increasing demands for efficiency, sustainability and productivity, come new technology developments to optimize the baking process.
RBS has developed a cracker-baking replacement for traditional DGF ovens – the Emithermic XE Oven. This technology is innovative because it eliminates all ribbon burners and delivers uniform heat distribution for an even bake across the width of the oven. It also allows for accurate moisture control, which is critical for a crispy cracker texture.
RBS specialists explain what makes this technology step a leap in cracker baking: “Traditional DGF cracker ovens are more difficult and costly to operate and maintain, and often produce an unevenly baked product. Operators must adjust and maintain a large number of ribbon burners to make sure the product is baked properly.” By contrast, the new Emithermic XE replicates the baking principle of a DGF oven without the hassle of having to manage so many different ribbon burners. Traditional DGF ovens can have 30 control points in each zone, while the Emithermic XE oven has just 7. “The Emithermic XE oven design uses a centralized penthouse to deliver heat to Thermatec® panels and convection nozzles to deliver balanced heat to the product. Electric radiant heaters can also be used to deliver the high radiant component required to develop the flavor and texture of the crackers.”
”The Emithermic XE oven design uses a centralized penthouse to deliver heated air to Thermatec® panels and convection nozzles to deliver balanced heat to the product. Electric radiant heaters can also be used to deliver the high radiant component required to develop the flavor and texture of the crackers.”
RBS specialists
Advanced controls
Moreover, this oven also cuts energy consumption and emissions, improves process control and simplifies cleaning and maintenance. Like all RBS ovens, the Emithermic XE features RBSConnect. This is an Industry 4.0-aligned control system that eliminates variables inherent to operators manually finetuning the process. “Developed to simplify operations, RBSConnect automatically executes pre-set, recipe-driven controls. Bakers can easily configure and store recipe settings to ensure product and process consistency,” RBS specialists say. The RBSConnect system also monitors production in real-time and manages a Closed Loop Oven Control System that captures data on product flow rates, temperatures, energy efficiency trends, and other Key Process Indicators (KPIs). Ultimately, the system helps ensure a higher percentage of products with the desired characteristics and less waste on the line.
Emithermic XE at the RBS Science & Innovation Center
Emithermic XE oven at a glance:
+ Eliminates all ribbon burners
+ Improves product consistency
+ Automated, intuitive operator controls
+ Simplifies cleaning and maintenance
+ Humidity-controlled product zone
+ Gas ovens easily convert to electricity in the future
Easy cleaning and maintenance
The benefits of the Emithermic XE technology also extend to cleaning and maintenance. A DGF oven can have more than 300 burners, so cleaning and maintenance can be a serious undertaking. When each of these burners needs tuning or replacement, maintenance is time-consuming and can cause unplanned downtime and lost productivity. With fewer parts to maintain and integrated support from RBSConnect, the Emithermic XE oven makes maintenance simpler and more cost-effective. “Along with monitoring the product during baking, the control system also monitors the performance of oven blowers and motors, recording motor amps, speeds, runtimes, and more. With RBSConnect, operators are alerted to replace failing parts long before they result in costly line disruptions,” the specialists explain.
Forward-thinking technology
RBS developed the Emithermic XE Oven with sustainability in mind. After all, manufacturers installing the new oven will be using it for the next 20-40 years. Accordingly, the Emithermic XE Oven is available with a penthouse that can be powered by natural gas or electricity. Manufacturers that opt for the gas-heated version today can easily convert the oven to all-electric in the future.
An Emithermic XE Oven has been installed in the RBS Science & Innovation Center for trial runs with measurable cracker and process results.
