Supporting Salva Industrial in enhancing an energy-efficient oven control system

The challenge

In professional baking environments, batch sizes can vary significantly, affecting baking uniformity, increasing waste and driving up energy consumption. To address this, Salva Industrial developed the Flex Baking programme, capable of automatically adjusting oven parameters based on real-time process data.

In this AZTI–SALVA case study, the challenge was to further refine the Flex Baking system to improve oven energy efficiency and prevent temperature peaks. These peaks are particularly critical during the final stage of baking and tend to intensify when the product load is lower. The goal was to correct these thermal deviations and stabilise overall process performance.

The solution

AZTI supported SALVA in the comprehensive development of the new and enhanced Flex Baking programme. The design phase combined theoretical modelling with experimental trials carried out in SALVA ovens, comparing full-load baking with the Flex Baking mode.

During each trial, product core temperature and oven chamber temperature were continuously recorded. At the end of each test, bread quality was evaluated, including texture, colour and sensory attributes.

This cause-and-effect analysis enabled the creation of specific commands within Flex Baking that automatically adjust baking parameters in real time. The system integrates the full-load reference curve with the oven’s actual temperature at each moment, dynamically adapting the baking process.

This approach delivers a more stable, energy-efficient process while maintaining optimal product quality under any load condition.

The results

The upgraded Flex Baking programme dynamically regulates air circulation and oven temperature, regardless of product quantity or size. This results in more uniform baking, reduced waste and a significant improvement in final product quality.

Energy efficiency is enhanced through automatic adjustment of the power required in each cycle. In addition, the programme increases operational flexibility, optimises baking times and simplifies operation for staff.

Overall, the technology enables bakeries to produce more and better, achieving a more agile and efficient process.