Scenario summary
Cookie, cracker, biscuit and confectionery factories run continuous bake lines producing 50,000–200,000 units per shift on 600 × 400 mm bakery trays. Soil profile: carbonized sugar, baked butterfat, sometimes chocolate or jam residue. The bakery industry’s worst-case wash challenge.
The cleaning challenge
Carbonized sugar is the hardest residue in commercial baking. Standard cycles often leave caramelized bottom-of-pan deposits that require pre-soak and extended detergent contact. Manual cleaning at cookie-factory throughput is impossible — 5,000 trays per shift would consume 8+ workers if done by hand.
Recommended PTW-1900 setup
Chamber: Standard 750 × 1000 × 1900 mm.
Heating: Electric 70 kW.
PLC profiles:
- Standard 6-min — light sugar residue (sandwich biscuits)
- Heavy 12-min with pre-soak — carbonized sugar (caramel, gingersnap, hard-baked cookie)
- Allergen Reset — peanut, dairy, gluten cohort changes
Detergent: Food-grade alkaline pH 12.2–12.5 (the stronger end — carbonized sugar requires aggressive alkaline emulsification). Acid rinse after heavy cycle to neutralize residual alkaline.
Throughput: 45 trays × 6 cycles/hour (Heavy cycle) = 270 trays/hour. For 5,000 trays/shift, plan 1 PTW-1900 running ~10 hours, or 2 machines in parallel.
Accessories: Heat recovery (essential — Heavy cycles are energy-intensive), pre-rinse spray-arm at loading station to remove loose debris before chamber load, filtered recirculation to catch sugar crystals.
Expected ROI
- Labour savings: 5 workers → 1 part-time = ~$140,000 annual
- Higher operating cost vs Standard: ~$8,000 (Heavy cycles use ~50% more energy)
- Net annual savings: ~$125,000
- Payback: ~5 months
Cookie factory FAQ
Q: Our cookies use silicone-coated pans. Heavy 12-min cycles — coating wear? A: No. Coating wear is from abrasive scrubbing, not from mechanical washing. Heavy cycles are time-extended, not abrasion-intensive.
Q: Chocolate residue — alkaline-soluble? A: Yes. Chocolate is fat + cocoa solids + sugar — all alkaline-soluble. Standard 6-min handles fresh chocolate residue; Heavy 9-min handles set chocolate residue.
Q: Can we wash silicone baking mats (Silpat-style)? A: Yes. Lay flat on trolley shelf or hang. Standard 6-min cycle. Inspect for damage after each cycle — silicone mats with cuts or tears get caught in the rotating chamber.