Cleanroom with 100% energy recovery from the back process

ÖLZ the Master Baker has set new standards in the production of baked goods such as braided bread and toast in collaboration with the internationally active engineering company NETZER GROUP from Feldkirch (Vorarlberg, Austria).

As the general planner for building technology, NETZER GROUP, specialized in cleanroom technology, took over the complete planning of building services, including cleanroom facilities, and successfully completed the implementation during ongoing operation up to commissioning.

One of the central requirements was to recover almost all of the energy generated during the baking process in terms of circular economy and climate neutrality. With the expertise of NETZER GROUP, this has been achieved. For ÖLZ the Master Baker, this means 100% energy recovery from the baking process. This leads to a significant reduction in gas usage and thus a reduction of approximately 245 tons of CO2 annually – an amount comparable to the gas consumption of 141 households. Consequently, energy costs and CO2 emissions for the company are significantly reduced.

Florian Rusch, Head of the Energy Management Team at ÖLZ the Master Baker, emphasizes: “Through an innovative process to recover waste heat from our new toast and braided bread baking lines, we make a substantial contribution to energetic circular economy.” These measures are part of ÖLZ the Master Baker’s comprehensive sustainability strategy, which also includes switching to 100% renewable electricity generated from hydropower in Vorarlberg.

Another milestone is the extension of the minimum shelf life without preservatives. This is made possible because, prior to packaging, residual heat and moisture that could promote mold growth are vented out by specialized ventilation systems. Essentially, from the oven through slicing to packaging, the products are protected from mold spores under nearly sterile conditions, which extends the shelf life of toast bread by up to two weeks. While other manufacturers add alcohol to the dough, ÖLZ the Master Baker achieves this through state-of-the-art cleanroom technology.

The planning and implementation of the project was a challenge, especially coordinating the building services with the requirements of the plant technology supplied by various companies across Europe. Given the complexity and the multitude of technical infrastructures, the NETZER GROUP project team opted for collaborative 3D planning. This ensured a smooth construction process, adherence to deadlines, and minimized additional costs, such as those caused by modifications.

For large systems, efficient cost management is essential. This requires knowledge of where and how it is feasible. NETZER GROUP has this expertise. For example, the use of a certified BUS system to control the mechanical smoke dilution system, which covers 19 smoke zones and operates with six fans, resulted in a significant reduction in procurement and maintenance costs.

The cooling is provided by machines using natural refrigerants, specifically ammonia (NH3 / R717). Due to its toxic and flammable properties, strict safety regulations must be meticulously followed.

Despite the challenges posed by the COVID-19 pandemic, the project was able to go into operation on schedule after 16 months of construction, thanks to experienced planning, documentation, and optimal communication with customers, suppliers, and contractors. ÖLZ the Master Baker and NETZER GROUP are thus setting a new standard in baking technology and sustainability.