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Why build the oven locally?

The cost of a quality imported baking oven will be approximately 40% of the total cost of a cracker line and up to 50% of the cost of a short dough biscuit line. Many international manufacturers of high-quality large ovens are located in high-cost environments, Europe, USA, Japan, Korea. Local manufacture offers important cost savings.

FIG 1/Leading image: Baker Pacific Direct Gas Fired / Indirect Radiant oven

A considerable proportion of the oven cost is in building the steel structures, baking chambers, heat exchangers, frames, covers and insulation. This work can be carried out successfully in many countries. There is no need to import large steel fabricated items with high capital cost, which can be manufactured successfully locally.


FIG 2 Direct Gas Fired Baking Chambers


FIG 3: Oven assembly with completed baking chambers and burners

Most biscuit oven manufacturers now assemble their ovens into complete modules before shipment. This reduces the time required on site to assemble the oven. However, it results in most of the assembly work being carried out in a high-cost environment and in incurring high shipping costs. Shipment of a typical oven may require 10-20 containers with both cost and time disadvantages to the project. The capability to manufacture ovens locally in the growing markets is an important advantage.

  • Reduced fabrication cost
  • Reduced import duties
  • Low shipping cost
  • Oven assembly in a lower cost environment
  • Part payment in local currency
  • Establishment of a local service capability

Building baking ovens locally: the Tasks and Team

FIG 4: The tasks and team

The team and experience required

Project manager

Mechanical engineering
Biscuit production
Purchasing

Design engineer

Mechanical engineering design
Software: CADCAM, Solid Works or equivalent Steel
Fabrication experience: Pneumatic systems, conveyor drives / transmissions

Electrical Engineer

Control and safety systems and components
Temperature control systems
Pneumatic systems for conveyors, drives and transmissions
PLC and PID system software Commissioning experience

Local Manager

Language, technical, commercial, financial experience

Installation Engineer

Fabrication / installation experience

Manufacturing drawings

Layout drawings are produced in Solid Works and Corel Draw to set out the design concept.
A layout drawing is then made to meet the customer’s requirements.
Following an agreement, a drawing is made showing foundations and installation details.

Control and safety systems

For hard wired control panels, wiring diagrams with parts lists are produced by the electrical engineer. The contractor will make AutoCAD drawings for approval and inclusion in the Operation Manual. For PLC controlled ovens, software is provided by a specialist contractor

FIG 13 Electrical control panels from our contactor Qiyuan, China

Contractors

Baker Pacific have manufactured ovens in China, India and Indonesia. The projects rely on having a first class local manager, conversant in technical, commercial, financial matters as well as language.

To select a suitable local contractor, we consider:

  • Location /communication
  • Capabilities: steel fabrication and assembly / factory space
  • Quality standard for food industry
  • Drawing standards and language
  • Purchasing of materials and components

FIG 14 Fabrication work in China

FIG 15 Indirect Radiant heater module made in India

Purchasing

Purchase Orders are placed on our contractors and suppliers detailing specification, price, terms of payment, delivery and commercial terms, for example guarantees. Currency may be in USD, Euro, GBP, local currency.

  • Bearings
  • Burners
  • Clamping elements, chains, sprockets pressure switches.......
  • Electrical equipment and panels, PLC thermocouples, UPS
  • Motors and gearboxes
  • Fans and Blowers
  • Gas equipment
  • Insulation and seals
  • Oven bands
  • Pneumatic equipment
  • Powder coatings

 

Summary

  • The baking oven represents the major part of the investment for a biscuit, cookie and cracker production line.
  • The major suppliers internationally manufacture in high-cost environments in Europe, USA and Asia. There are major cost benefits in establishing a capability for local manufacture.
  • A small team of engineers is required. Most medium to large biscuit manufacturers and bakery oven suppliers will have suitable capability.
  • At Baker Pacific, we continue to provide technical support, design and manufacturing drawings for local manufacture
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