Food Production · Bakery & Snacks
Oven Temperature Zone Control
Tighten zone control across 6 oven zones to cut quality deviations and gas consumption simultaneously.
How Allie Works Here
From signal to action in real time.
The Process Control agent reads 24 zone temperature historian tags at 2-second intervals and computes a product-specific thermal profile deviation score relative to the certified master recipe stored in the MES. When zone 3 top/bottom delta exceeds ±3°C for more than 45 seconds, the Energy Optimization agent cross-checks burner fuel consumption and recommends a burner trim setpoint to restore balance without over-firing. The Quality Control agent monitors FLIR surface temperature readings and issues a hold recommendation to the packing line if surface variance exceeds the specification envelope. The Predictive Maintenance agent tracks burner damper actuator response times and igniter health across all 6 zones, surfacing wear signatures into the Maintenance agent's work-order queue with linked manuals and prior fault history before they cause a zone trip.
Machines & Connectivity
OT-connected, protocol-native.
6-zone continuous baking oven; each zone independently heated and dampered
Zone temperature and conveyor speed PLC; primary control loop owner
Real-time surface temperature profiling of product leaving zone 5
Process Variables
The signals Allie monitors and moves.
| Signal Name | Historian Tag | Unit | Baseline | Optimized | Target |
|---|---|---|---|---|---|
| Zone 3 Top Burner Setpoint Delta | OVN01.Z3.TOP.DLT | °C | ±8 | ±2 | Tighter |
| Product Surface Temp at Zone 5 Exit | OVN01.Z5.SURF.TMP | °C | 162–188 | 170–178 | Tighter |
| Conveyor Speed | OVN01.CVY.SPD | m/min | 4.2–4.8 | 4.5–4.7 | Tighter |
| Natural Gas Flow | OVN01.GAS.FLOW | m³/h | 84–102 | 76–88 | Lower |
OVN01.Z3.TOP.DLTOVN01.Z5.SURF.TMPOVN01.CVY.SPDOVN01.GAS.FLOWIn the Field
"a high-volume cracker and biscuit manufacturer running three tunnel ovens across two production shifts"
Deployed at a high-volume cracker and biscuit manufacturer running three tunnel ovens across two production shifts. The results above reflect production data from the 60–90 day period following full deployment.
Next Step
See what your lines are actually capable of.
A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.