Global systems supplier, GEA, is producing preassembled oven modules for quicker installation at customers’ plants. According to GEA, it can reduce installation time to as little as 20 days.
In the dynamic bakery industry, efficiency is critical to the production process. To overcome complexities in the installation process and reduce downtime, GEA has launched its pre-assembled module ovens at a production facility in Verona, Italy.
The plug-and-play-service was developed from an initial study by GEA engineers, that used a 65 m long and 1.2 m wide oven. The study found that when considering the conveyor belt, fuel, and heating system, installation of a disassembled oven took around 45 days.
The plug-and-play option reduces the installation time to roughly 20 days. This study looked at both the mechanical assembly and electrical connections, but did not include commissioning.
GEA senior director Project Management, Mario Da Ros, said, “The aim of plug-and-play ovens is to speed up the installation process, in order to reduce production downtime at the customer facility.
“Preassembled ovens are a great way to ensure a high-quality installation phase of our ovens, given that it is mainly carried out at our own facility.”
The plug-and-play option was demonstrated during the installation of a large oven for an overseas customer.
GEA senior director Project Execution, Gianluca Dolci, said the company delivered a 124 m long and 1.6 m wide oven to an Indonesian client.
“We managed to display all 58 pre-assembled modules in five days, which meant GEA electricians could start working on the oven at the customer’s site at the same time as GEA mechanics, a huge advantage that guarantees a much faster installation,” Dolci said.
The installation of the oven was conducted in half the usual timeframe, taking four weeks instead of eight due to the pre-assembled modules.
This method reduces labour costs, in terms of mechanics and electricians needed for installation, and reduces the need for highly specialised personnel. The most complex operations are carried out during the pre-assembly of the modules at GEA’s production site.
It also increases safety standards, as operators no longer come into contact with the rock wool used to insulate the baking chamber. Without rock wool management, it is no longer necessary to isolate the production environment to avoid the risk of contamination with other production lines in operation during the installation process.
