New machine design

The E-Bake G2 can be built with various heat transfer modes, so it can provide various levels of flexibility, as required. For example, it can be customized to incorporate radiant electric heating, convective electric heat, radiant heat combined with air turbulence, as a combination of radiant and convective heating, or any mix of these, for any customization desired for maximum diversity of thermal profiles and product types. GEA: “Customers have a wide range of options, from fixed configurations for single-product lines to highly flexible setups for multi-product lines that can accommodate various products. There are even ultra-flexible configurations, where the heat transfer mode can be freely selected within multi-purpose modules.”

GEA’s new Kinetic Edge machine design was applied to the E-Bake G2 oven, a structural redesign that uses 64% less iron in the frame and baking chamber. GEA explains how this significant iron reduction in its structure was made possible: “E-Bake G2 is a completely new platform, designed from the ground up rather than being a modification of legacy gas-based ovens. Its development was guided by the principles of GEA Kinetic Edge design, with a strong focus on sustainability and the circular economy. The optimization of the baking chamber volume, made possible by the electric-only configuration, contributes to a reduction in raw materials such as iron.”

The redesigned baking chamber has a smaller volume, which minimizes heat loss and positions the heating elements closer to the product, improving thermal efficiency. Micro-convection technology is included in this oven, with localized air flow systems, which distribute uniform heat and reduce temperature fluctuations across the baking surface. “The innovative micro-convection principle reduces heat loss along the baking zone by generating heat as close as possible to the point where it is transferred to the products,” GEA specialists highlight.

Thermal bridges – pathways through which heat can escape – have been minimized. “Thermal bridges are usually one of the factors that reduce the efficiency of traditional baking ovens. GEA Bakery has always designed ovens to minimize heat loss; with the reduced baking chamber volume and the new design of radiant electric resistors in the E-Bake G2, this performance has been further enhanced,” GEA explains.

Additionally, the electric resistances have been reconfigured for targeted heat generation, which allows consumption to be lower by up to 40 %, compared to gas-fired models.

At the same time, the new concept allowed this oven to use fewer components. As part of the GEA Kinetic Edge approach, GEA Bakery utilized standardized modules that can be configured to order, to ensure efficiency and sustainability. The oven’s modular architecture is key to its performance, GEA says, improving both energy usage and baking consistency.

Cleaning and maintenance operations are facilitated by a design that offers ample access to the baking chamber and the ability to extract the bottom elements, GEA highlights, adding that “Advanced resistor control and preventive maintenance features are now also available.”

According to Marco Girimondo, Product Manager at GEA, “Our ‘Voice of the Customer’ research highlighted growing interest in sustainable baking solutions, particularly electric baking. However, customers face high operational costs due to energy tariffs and capital costs for plant infrastructure upgrades. The E-Bake G2 directly addresses these concerns by significantly lowering energy consumption and reducing both installed power and total cost of ownership compared to conventional electric ovens.”

Thanks to its design, the oven offers fast, plug-and-play installation. Each module is preassembled with its electric cabinet mounted on top, eliminating the need for extensive on-site electrical wiring. This configuration can reduce installation time by up to 70%, based on a reference 90-meter-long electric oven with seven baking zones. From a process perspective, operators will experience a smooth transition, as the control points remain the same as those on previous-generation ovens. “They can start with the current settings and fine-tune the recipe to optimize parameter setup and reduce energy consumption,” GEA explains.

These improvements make the E-Bake G2 a lighter oven system, more sustainably made and easier to recycle, with the added bonus of a new visual aesthetic.