Food Engineering logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • TOPICS
  • EXCLUSIVES
  • MEDIA
  • FOOD MASTER
  • EVENTS
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest Headlines
  • Manufacturing News
  • People & Industry News
  • Plant Openings
  • Recalls
  • Regulatory Watch
  • Supplier News
  • PRODUCTS
  • New Plant Products
  • New Retail Products
  • TOPICS
  • Alternative Protein
  • Automation
  • Cannabis
  • Cleaning | Sanitation
  • Fabulous Food Plants
  • Food Safety
  • Maintenance Strategies
  • OEE
  • Packaging
  • Sustainability
  • More
  • EXCLUSIVES
  • Plant Construction Survey
  • Plant of the Year
  • Sustainable Plant of the Year
  • State of Food Manufacturing
  • Top 100 Food & Beverage Companies
  • MEDIA
  • Podcasts
  • Videos
  • Webinars
  • White Papers
  • EVENTS
  • Food Automation & Manufacturing Symposium and Expo
  • Industry Events
  • RESOURCES
  • eNewsletter
  • Custom Content & Marketing Services
  • FE Store
  • Government Links
  • Industry Associations
  • Market Research
  • Classified Ads
  • EMAGAZINE
  • eMagazine
  • Archive Issue
  • Advertise
Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!
Processing

Cooking Technology

Three steps to more efficient cooking

By Ben Kop
Smart cooking technology
February 11, 2022

As demand grows for more efficient and sustainable methods of food production, the latest industrial cooking technology has the potential to transform the mass production of roasted, breaded and smoked products.

Over-cooking caused by temperature variation across the belt is a challenge for food manufacturers due to its detrimental impact on yield and product quality. It’s a major drawback of ovens with air velocity going in only one direction. Food manufacturers want to create a product of the same quality as a conventional rotary spit, but on a much larger scale so that anyone, anywhere can walk into a supermarket and enjoy well-cooked meat or poultry.

The introduction of spiral ovens with improved airflow that goes from top to bottom and left to right has changed the ball game in terms of quality, efficiency and yield. To further optimize capacity, three-phase technology has been developed with even more precise process control. Three-phase spiral ovens can be used for roasting meats, cooking crispy non-fry coated products, such as chicken wings, formed uncoated products, marinated products, steamed products and dried or smoked meats and fish. 

This new generation of ovens provides an extremely accurate, high performance solution which pushes the art of cooking to produce even more of what the food industry wants—increased yield and improved sustainability, as well as high quality products.

Optimized airflow is the key. A combination of horizontal and vertical airflow means maximum precision and flexibility in controlling the cooking conditions to best suit the application. Heat is distributed more evenly across the whole width and length of the belt providing uniform cooking. The high level of controllability means that products can be cooked in a way that provides reproducible results time after time.

For example, a three-zone cook range, like GEA’s CookStar, can offer an increase in yield of up to 3% or 5%, depending on the applications, with fewer overcooks and shorter cooking times compared to its predecessors. Manufacturers can set each zone in the oven to a precise recipe, providing more targeted cooking and consistent browning, while reducing any waste caused by over cooking. 

An enhanced impingement zone gives a higher air volume for greater cooking impact and efficiency, meaning lower power consumption. Yields can also be improved for coated products, as the improved airflow enables a crispier coating without drying out the juicy product core. Generating extra heating capacity translates into the potential  of increased throughput. 

So what benefits are provided in three-phase cooking? It’s the ability to accurately control the cooking parameters. The first phase utilizes the latent heat of steam to cook quickly and gently, keeping meat succulent by preventing moisture loss. Then, the impingement zone blasts the product with hot, dry air to remove excess humidity and prepare the surface for coloring or roasting  without drying out the core. The final phase develops the coloring to complete the process, cooking products to perfection.

However, three-phase cooking equipment should not be a mystery. Training is important so that operators get the best out of the equipment to capture the authentic flavors of each product, which requires correct timing, airflow, dewpoint and temperature within the oven.  Since every manufacturer has its own unique process or product, high transparency and expert back-up are crucial. 

The optimum setting for any individual product is a compromise: a high dewpoint improves yield but prevents browning   while a lower dewpoint browns the meat but dries it out. The latest three zone ovens now come with smart climate and exhaust systems that allow increased flexibility and sustainability.

Intelligent exhaust systems monitor the environment within the oven continuously, adjusting the volume of exhaust air as needed to maintain the precise atmospheric conditions required for optimum cooking. By only using energy exactly as and when it is needed, this technology can also reduce heat and steam losses, helping to reduce power consumption. 

All in all, the emerging generation of industrial cooking technology is enabling food processors to add a high degree of flexibility to their production lines. The increased use of ‘intelligent’ systems is giving manufacturers the ability to control distinct parameters according to changing consumer demand, while still providing high productivity, sustainability, reliability, and total security of outcome. 

KEYWORDS: cooking equipment cooking ovens three-phase cooking

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Ben Kop is a Food Technologist at GEA, one of the largest food system suppliers.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    Latest headlines
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Cleaning | Sanitation
    By: Richard F. Stier
Manage My Account
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

Food Plant Openings and Expansions June 2025

Food Plant Openings and Expansions June 2025

Celebrating Women in Engineering: Shalima Sreenath

Celebrating Women in Engineering: Shalima Sreenath

Celebrating Women in Engineering: Samara Heaggans

Celebrating Women in Engineering: Samara Heaggans

Food Plant Openings and Expansions May 2025

Food Plant Openings and Expansions May 2025

More Videos

Popular Stories

Cargill Cocoa Plant

Cargill Invests in its Cocoa Supply Chain

Campbell’s Utah plant

Going for Gold(fish): Inside The Campbell’s Company’s $160M Cracker Plant Expansion

Chicken Alfredo Listeria Products

Listeria Outbreak Connected with Pre-Made Chicken Alfredo Meals Results in 3 Deaths

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 17, 2025

Refrigerated & Frozen Foods’ State of the Cold Chain

On Demand Kelley Rodriguez, Editor in Chief of Refrigerated & Frozen Foods, will be joined in this 60-minute webinar by industry experts to help unpack the latest research.

July 10, 2025

Smarter Innovation With AI: How the F&B Industry Can Stay Agile

Join our webinar to explore how practical AI solutions are helping leading brands reduce compliance risks, streamline reformulation and accelerate time-to-market.

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • digital transformation

    The Digital Path to a More Efficient and Sustainable Food and Beverage Industry

    See More
  • NXTCOLD systems

    Making ammonia safer and more efficient in refrigeration applications

    See More
  • Cold Chain

    Internet protocols make the refrigerated supply chain more efficient

    See More

Related Products

See More Products
  • food crime.jpg

    Food Crime: An Introduction to Deviance in the Food Industry

  • GlobalData_logo_blue_header.png

    USA: Food & Grocery - Market Shares, Summary & Forecasts to 2023

See More Products
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!