1. Why build the oven locally?

Baker Pacific Direct Gas Fired / Indirect Radiant oven

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.

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.

Direct Gas Fired Baking Chambers

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

2.  Building baking ovens locally: the Tasks and Team

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

Our Chief Engineer, Local Manager and Contractor

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 agreement, a drawing is made showing foundations and installation details

Layout drawing for a Direct Gas Fired oven section

Oven foundation drawing

The assemblies and parts are drawn in Solid Works with 3D pictures. The software allows us to check all dimensions and the assembly of parts.

Solid Works drawing for DGF oven

Selected component from the assembly drawing: Inspection Door

Layout showing position of the inspection door in the baking chambers

Component assembly

Exploded view of assembly

Manufacturing drawing for an individual  part

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

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

Fabrication work in China

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

Shipping

It is important to select a shipper who will handle a wide range of components from multiple sources. Our shipping has been managed by PT Geodis Wilson and DFS. They arrange pick up from our contractors anywhere in the world, shipment and delivery CIF to the customer.

Installation

The oven is delivered in ‘kits of parts’ corresponding to the sequence required for the installation.

Baker Pacific provides two supervisory engineers for installation and commissioning. They supervise the work carried out by local staff provided by our customer.

Installation of a Baker Pacific Indirect Radiant Oven with Heat Recovery System

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.

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