Which Deck Oven is Right for Me?

This is a question we hear all the time.  As one looks for an oven to meet their production needs,  there are often many questions as to which is the “right” oven to purchase. Differences in design can have an impact on the quality and quantity of product that you can produce. There are three basic types of gas/oil fired, stone hearth deck ovens. While they may appear similar from the outside, each has its own baking characteristics and advantages. The major differences are how the heat is distributed to the decks, the type of materials that are used in the construction, and how they generate their steam for the baking process.


I. CICLOTHERMIC:
Cyclothermic ovens circulate hot air between and around the decks either indirectly through a heat exchanger or directly from the burner. Other than the baking surface, these ovens are typically all steel construction with mineral wool type insulation. The advantage of the cyclothermic is the ability to change temperatures rapidly. Some also have the ability to regulate the temperature on the top 1 or 2 decks to a lower temperature than the bottom decks to accommodate various products at the same time. Because air does not hold heat very well, it is not considered to be a very efficient means of heating.


Cyclothermic ovens are not usually recommended for baking 'heavy' products. As with a hot air heating system in a home, when the burner shuts off, there is a tendency for the oven to cool down rapidly until the thermostat calls for more heat. Then when the burner re-ignites or goes back to high flame, the temperature will rise again quickly. This produces more oven temperature fluctuation than might ideally be desired for baking breads with longer bake times, especially if you are using steam and desire a good thick crust. The oven will also be limited in the amount of production due to the time required to recover from the heat loss.


II. VAPOR TUBE
Vapor Tube ovens circulate heat through the use of a series of sealed, thick wall tubes that contain approximately 1 liter of water. Each tube surrounds the oven chamber and as well as passing above and below the decks. The bottom portion of each tube rests directly on the burner chamber. The water inside the tube quickly boils, turning to steam. By natural thermodynamics, the steam circulates through the pipes, radiating its heat through the oven walls and stone hearth. As the heat is transferred, the steam returns to the liquid state and returns to the bottom of the tube, where the entire process begins again. The heating system requires no moving parts or fans to distribute the heat, thereby eliminating a potential source of uneven baking and required adjustment and maintenance. Vapor tube ovens also provide excellent baking quality since the tubes themselves serve as an excellent thermal mass. Two versions of vapor tube construction are:

• All Steel construction models:  For many years, most of the vapor tube ovens installed in the U.S. were of all steel construction and performed well in many situations. As demand for hearth breads has increased, however, many bakeries find that an all-steel oven cannot maintain the heat necessary for this type of baking and steaming. This can result in a greater degree of change in baking properties or unevenness of baking after 6 hours or so of heavy production. The recovery of the steam system can also be adversely effected by the lack of heat retention.
  


• Steel and Cement Construction: Many European bakeries have long used a combination of steel, cement and brick to achieve the same baking properties as a brick oven. In essence the brick and cement act as a “heat sink”. In this way, when the oven is loaded with bread, and steam is introduced into the chamber thereby absorbing the chamber's available heat, the brick and cement supply a continuous, smooth flow of heat without the burner having to try and play “catch up".
  
  Some ovens utilize brick in the fire chamber while using mineral wool or other insulation in the walls. These are usually considered superior to the “all steel” and cyclothermic ovens for the production of most hearth breads requiring good properties of heat retention and repetitive steam cycles.
  
  For the ultimate in “brick oven baking”, ovens are available with cement-lined walls and roof panels. Filling the walls and roof panels with cement (and thereby surrounding the entire baking chamber with thermal mass) retains the greatest amount of heat and is preferable for baking large or heavy breads and for heavy production schedules.
  
  Steel ovens without the cement do not have the ability to store nearly as much heat and therefore are much more dependent on the burner to immediately supply the heat needed. This gives a very different baking characteristic than the traditional brick oven. Most bakers, who have used both styles of vapor tube oven and wish to closely simulate an actual brick oven, prefer the cement and brick design. Of course it is easiest to move an oven without any cement at all and one needs to weigh the importance of this in choosing the proper oven type.

III. THERMOIL
Thermoil Ovens generate their heat in a heat exchanger, outside of the oven, by heating a special oil composition in an oil heater or “boiler” (although not actually a boiler since the oil does not boil). This heated oil is then pumped through radiators inside the oven decks, radiating the heat for the baking process. While certainly the most expensive deck oven to purchase, there are several advantages to this style of oven. Because fluid is being pumped through radiators the flow can be controlled for adjustment of heat in various zones of the bake chamber. In addition, ovens of greater capacity than cyclothermic ovens can be built. The fluid is also an excellent conductor of heart, providing a high level of energy efficiency. Also because the burner is remote from the oven, it can be located in a clean area of the bakery and produces no noise in the bake room.

GENERATING OF BAKING STEAM
Deck ovens usually generate the steam for the baking chamber from the same heat source as the baking heat …the burner. The major difference in deck ovens will be, where the steam generating units are located and their ability to produce consistent steam in rapid cycles to accommodate the constant loading of the oven in high production situations. The best application is to have heavy duty steel boxes filled a heat retaining material, such as construction grade steel bars (rebar) directly in the hottest part of the heat production system. In a vapor tube oven this will be under the bottom deck. As an alternative, some manufacturers place troughs on the side of each deck, but it is generally thought that in mid to large size ovens this is not as effective and does not have the ability to “recover” quickly enough bake after bake. In any system, it is important that the steam system be accessible for cleaning and occasional decalcifying, if necessary.


Let us help find the right Deck Oven for you!
Give us a call or visit us online:
EMPIRE BAKERY EQUIPMENT
800-878-4070 • 516-681-1500
www.empirebake.com

Cupcakeries are Taking Over the World!

These sweet little treats aren't just for kids anymore! Gourmet cupcake shops have seen a sharp rise in popularity of late, and local bakers are starting to take notice.

"They are everywhere . . . like ants," said Leslie Goldman-Poyourow, a 14-year baker who operates Cakes by Leslie in downtown Bethesda, Washington.

There does seem to be a lot of them. From New York to L.A., Las Vegas to Chicago, cupcake shops are popping up like wild fire; and their customers can't get enough!

But what's driving the boom? Variety, for one thing. "Cupcakers" are motivated to produce new and exciting flavor combinations in order to separate themselves from the growing pack. Kari Haskell of Retro Bakery in Las Vegas is a great example. Her flavor menu boasts some of the most unique flavors around - like Apple Cider, Cinnamon Toast, Chocolate Covered Banana and Maple Bacon.

Convenience is a factor, too. There's no need to worry about mess or portion control when you can set out a beautiful cupcake display at your next wedding, baby shower and other social gathering. Each of your guests gets their own little self-indulgent treat, and you know exactly how many servings are available.

The economy plays it's part as well. Customers crave a simple, inexpensive pleasure at a time when the economic news seems so discouraging; and cupcakes fit that bill nicely! Paul Sapienza, VP of the Retail Bakers of America, seems to agree: "[Cupcakes] are an economic treat, which helps out in the recession. They are a little decadent, so you get cake, frosting and sometimes filling all at the same time."

Whatever the reason, there's no denying that cupcakes have hit a sweet spot in the hearts and stomachs of Americans everywhere. So the next time you need a fix, be sure to sniff out the new Cupcake Shop in your neighborhood - and pick up a Mocha Java Cupcake for me!

Empire Bakery Equipment supplies everything from mixers and ovens to utensils and accessories to 'Cupcakeries' and Bakeries across the country. We've been America's leading supplier of bakery and production equipment for over 30 years! Visit us at http://www.empirebake.com for more information, or give us a call at 1-800-878-4070.

How to Take Advantage of the Challenging Economy to Bake a Better Tomorrow

Your customers have a choice.

We see it every day.  In the news,  at the store,  filling up at the pump - reminders of the recession that's taken hold around us.  Unemployment is up, consumer confidence is down, and the global economy is struggling. To say that the financial climate is 'grey' is putting it nicely!

Admittedly, businesses everywhere are feeling the pinch.  For many of them, the first reaction is to cut spending any way they can.  Bakeries, pastry shops, bagel stores and pizzerias alike are all looking for ways to save. 

Unfortunately,  recessions are fueled by fear;  and that can lead to poor decision making.  While it may be both necessary and wise to trim the proverbial "fat" from your business, doing so with only short term benefits in mind can be detrimental.  What question should you really be asking yourself right now?

“Do I plan to be in business 5 years from now?”

If the answer to this question is "Yes!", then here are some things you can do in these troubled times to help ensure a brighter and more prosperous future!

Give Your Front-end a Facelift

If you run a retail operation, take advantage of these slow traffic days to give your front-end a makeover!   A fresh coat of paint, maybe some new lighting and updated decor can all be done on a budget, and they can go a long way to making  a huge impression. 

Think outside the box as well.  If  you're struggling with old refrigerated displays that keep shutting down on you, updating it may be just what you need.  Not only will a new display units be aesthetically pleasing to your customers, but more efficient models may actually save you on maintenance and energy costs over time.

Remember, if you're store looks like it's going out of business, then your customers may assume that you are.  A fresh look can show your customers that you care about your shop and their experience when they come to visit.  Make it a pleasant one, and they'll keep coming back for more!

Update Your Marketing Programs

Unfortunately, marketing dollars are usually the first casualty in a recession.  However,  the down-time of a sluggish economy gives you a great opportunity to review and revamp a lot of your existing material.  Pull out some of those old ads of yours and see if you can't reuse some of them.  Just like your store front, a little update can go a long way.

Take advantage of all of the opportunity that the Internet has to offer as well.  A well designed and informative website can go a long way toward getting you good placement in the search engines.  Social media sites such as LinkedIn, Twitter and Facebook are free, and they are a great way to build your network and communicate with your customers.  Even pay-per-click campaigns like Google Adwords or Microsoft Advertising (via Bing.com) can offer you great exposure at a very reasonable price.

Keep in mind that the everyone is feeling the heat in today's economy.   That means that media outlets and design houses are out there vying for work, too - and that could mean big savings for you.  Price out  things like website redesigns, print ads, flyers, even TV and radio spots.   Shop them around a little bit and you might be pleasantly surprised at the deals you can find!

Replace Old Production Equipment

Cash flow is tight and fuel costs are on the rise.  That old, inefficient  equipment you have running in the back may be bleeding you dry - and you may not even realize it. Efficiency is the key to profitability, and cost effective, quality equipment will save you time and money in repairs, maintenance and excessive labor fees .

Consider this; bakers all around the country are finding that a fuel efficient deck oven can save more in fuel costs than the lease payment itself,  and can even return money to their bottom line!  That money that can be used to offset the increased cost of ingredients and other expenses. In addition, because there are no moving parts and no boiler to sustain, maintenance costs and related downtime are held to a bare minimum.

A new cookie depositor can offer substantial savings as well.  It's ease of use and highly efficient design can do the work of three people at significantly less expense.  Even consider something as simple and affordable as a new divider/rounder that will help you increase productivity and maintain consistency throughout your production process.

The truth is that customer satisfaction is essential to your businesses survival.  New equipment will give you the quality and consistency you need to keep your customers coming back for more.

Get Out There!

Network, network, network!  Get out in front of your customers and let them know you're there!

If you're a wholesale operation, take advantage of some down time to get out of your facility and go visit existing customers - or even pop in on some new ones.  Sometimes all you need to do is stop in and shake hands, and your customer will remember the effort you made.

If you own a retail location, don't be an absentee owner.  Make sure you're in your store front interacting with your customers.  Talk to them, find out what they like or don't like about your operation.  Also, consider participating in local community events.  Donating some food or your time is a great way to network with new and existing customers - and free food will certainly make them remember you!

Conclusion

These troubled economic times are scary for sure; but for those of us willing to work for it, opportunity can still be found all around us.  Give your store a facelift and leave a lasting impression with your customers.  Take advantage of competitive pricing to update obsolete marketing material.  Replace old bakery equipment and save big on fuel, labor and maintenance costs.  Most importantly, get involved with your customers.  Remember that your customers have a choice.  Be sure to give them reason to choose you!

About Empire Bakery Equipment

Empire has been America's leading Bakery Equipment supplier  since 1977.  We supply successful bakeries all across the country with spiral mixers, deck & rack ovens  and a complete selection of production equipment.  We feel that the greatest measure of our success is your success!

Visit us online at http://www.empirebake.com,  or call 1-800-878-4070 to speak with representative today!

Direct vs. Indirect Water Chillers

In today's market, customers demand quality and consistency in your product. To that end, precision temperature control is key, making a good water chiller a must in any bakery. But how will you know which one is right for you?

When shopping for a water chilling system, you have many options. The first and perhaps most important choice you have to make is whether a Direct or Indirect system is best. What's the difference?

Direct Water Chilling Systems

A direct water chilling system utilizes a refrigerated "plate" or coil that is submerged directly into the tank of water to be chilled. Once the water reaches the desired temperature, it can either be pumped or gravity fed to its final destination.



Since the cooling medium and the tank are in direct contact with the water supply, they must both be cleaned frequently so as not to adversely affect the taste of the water or finished product. Additionally, a direct water chilling system must be maintained regularly to avoid any leakage from the cooling medium. If the coil or plate leaks, Freon will contaminate the water, ruining the finished product and posing a health hazard.

Finally, because the supply is not under pressure, water must either be pumped to its destination, or the tank must be placed high enough to rely on gravity. This can make a direct water chilling system difficult to clean and service.

Indirect Water Chilling Systems

Indirect water chilling systems separate the cooling apparatus from the water supply, creating a clean and hazard free water chilling method. Freon is passed through a coil that quickly freezes the water around it into a block of ice. The ingredient-water supply flows through the ice block within a separate stainless steel coil so there is no danger of contamination. With our indirect system, the separate tubing units ensure that the water supply and Freon can never cross paths.



Additionally, since the water supply is running through a coil, there is no collection tank to keep clean; and the flowing water provides more than enough pressure to avoid the use of either a pump or gravity fed supply methods. That means you can place an indirect water chilling system anywhere you need it, making it easier to clean and service.

Indirect Water Chillers have quite an advantage over Direct Water Chilling Systems. Owning an Indirect Water Chilling System means that you have no tank to clean, there is no danger of cross contamination, and no pump is required since the water is under normal water pressure. With our indirect system, higher productivity can be easily achieved, allowing you to make a better product, and higher profit with a smaller system.

 
Learn More About Indirect Water Chillers from Empire

Welcome to the Baker's Corner!

Empire Bakery Equipment is America's leading supplier of spiral mixers, deck ovens, cookie and pastry machines and production equipment to the bakery industry. Whether you bake breads and rolls, bagels, cookies, pastries, pizza or anything in between, Empire has the knowledge and experience to not only supply you with the proper equipment, but to support you on your way to success!

In an effort to provide continued support to the industry, we are proud to launch The Baker's Corner - Empire's new web log. Here we will provide you with industry news, product information, production tips and more to help you stay up to date and informed. At Empire, your success is our success!

Thank you for visiting our little corner of the Blog-o-sphere. Remember to keep your eyes here for the latest from Empire Bakery Equipment, and visit our site at http://www.empirebake.com for more!