Food Production · Bakery & Snacks

Oven Temperature Zone Control

Tighten zone control across 6 oven zones to cut quality deviations and gas consumption simultaneously.

−44%
Quality Deviations
−12%
Gas Consumption
−38%
Rework Rate

How Allie Works Here

From signal to action in real time.

Process ControlQuality ControlEnergy OptimizationPredictive Maintenance

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.

Haas-Meincke Tunnel Oven
Haas Group
OPC-UA

6-zone continuous baking oven; each zone independently heated and dampered

Allen-Bradley ControlLogix 5580
Rockwell Automation
EtherNet/IP

Zone temperature and conveyor speed PLC; primary control loop owner

FLIR A615 Thermal Camera
FLIR Systems
MQTT

Real-time surface temperature profiling of product leaving zone 5

Process Variables

The signals Allie monitors and moves.

Zone 3 Top Burner Setpoint DeltaTighter
OVN01.Z3.TOP.DLT
Baseline: ±8 °C±2 °C
Product Surface Temp at Zone 5 ExitTighter
OVN01.Z5.SURF.TMP
Baseline: 162–188 °C170–178 °C
Conveyor SpeedTighter
OVN01.CVY.SPD
Baseline: 4.2–4.8 m/min4.5–4.7 m/min
Natural Gas FlowLower
OVN01.GAS.FLOW
Baseline: 84–102 m³/h76–88 m³/h

In 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.

−44%quality deviations
−12%gas consumption
−38%rework rate

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.