IBT STIR User manual

IBT.InfraBioTech GmbH
Manual –Baking with STIR®
Baking with STIR®for
Rack ovens
Shop ovens
deck ovens
tunnel ovens for classical pastries
tunnel ovens for pizza
Customers
Manufacturer for ovens on the basis of domestic gas,
domestic fuel oil, electric energy or heat transfer oil with
high demand on high standards of quality and freshness.
IBT.InfraBioTech GmbH
Am St. Niclas Schacht 13
09599 Freiberg (Saxony)
phone [phone]
fax [phone]
www.infrabiotech.de
www.infrared-baking.com

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Contents
1 Mode of action of STIR®-technology ................................................................................2
1.1 General ......................................................................................................................2
1.2 Baking.........................................................................................................................2
2 Benefits ............................................................................................................................3
3 Rules for baking with STIR® .............................................................................................4
3.1 Baking phases ........................................................................................................4
3.2 Humidity .................................................................................................................4
3.3 Mellowness ............................................................................................................4
3.4 Temperature ...........................................................................................................4
3.5 Temperature measurement ....................................................................................4
3.6 Stick out- and flow temperature ..............................................................................5
3.7 Early skin formation and incrustation ......................................................................5
3.8 Increase in temperature .........................................................................................5
3.9 Short pre-streaming ................................................................................................5
3.10 Steaming ..............................................................................................................5
3.11 Core temperature .................................................................................................6
3.12 Shut down ............................................................................................................6
3.13 Incrustation ...........................................................................................................6
3.14 Steam exhaust .....................................................................................................6
3.15 Finishing baking ....................................................................................................6
4 Baking programs with STIR® ............................................................................................7
4.1 Oven type: deck oven ..............................................................................................7
4.2 Oven type: baking oven .........................................................................................10
4.3 Oven type: STIR®-tunnel oven ...............................................................................10
5 Comparison of energy consumption with STIR® vs. classic baking oven........................10
6 Comparison of furnace practice with STIR® vs. classic baking oven...............................11

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1 Mode of action of STIR®-technology
1.1 General
The energy emitted is absorbed in the resonance range in the radiated good: Compared
with standard thermal processing of pastries and foodstuffs with convection heat and classic
infrared, STIR®is more effective as the energy is largely transferred in the resonance range.
Thus, we offer you the ideal infrared solution for a wide range of pastries and foodstuffs for
thermal processing, with customised benefits in terms of energy efficiency and processing
time
1.2 Baking
Infrared emitters with STIR®cause the infrared heat to infiltrate the core of the bakery
product more rapidly.
Thus the required core temperature and the stabilization of the crumb are achieved more
quickly.
More moisture is retained in the baked product, which has a positive effect on its freshness,
taste and shelf life.
As the initial quality is better, it is possible to bake bread, rolls etc. with either a soft or a
crisp crust, as required, during the second baking phase.

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2 Benefits
Baked goods of the highest quality
Bread, rolls, cakes and pastries, pizza and
snacks
delicious looking
excellent taste
optimum moisture
longer lasting freshness
higher nutritional and vitamin content –
less harmful substances
Shorter baking times
Reduction of baking times of 25 to50%,
depending on baking products (for tunnel
ovens from 15 to 45%)
more flexibility and buffer time for the
baker
higher capacity for the same size of
oven
for the same capacity of pastries, the
oven is shorter and therefore more
cost-effective (for tunnel ovens)
Less energy consumption
energy savings of 15 to 20%,
depending on furnace practice and
bakery products (for tunnel ovens even
up to 30%)
Less baking losses
2 to 7% depending on the pastries
saving of flour and baking ingredients
Sources and Comments
2. Analysis of the WTD of the Bundeswehr Meppen: "Spectral
measurements and emissions performance in the wavelengths
range of 2 - 14 µm with blackbody emitter-calibration"
6. ɛ = 1 black body (100 %) : λ (3µm) = ƒ (700 °C) (optimal
wavelength for the absorption of water molecules)
Photos right: different types of STIR®-oven emitters

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3 Rules for baking with STIR®
For STIR® baking preferably radiant heat is used –whereas classic baking favours warm air.
TIP: If the baking on a STIR®-oven is processed in conventional way, the benefits of STIR®-
baking won’t appear at all or only partially.
In general: higher temperatures and more vapour in the beginning, but: different dough
compositions cause different baking systems!!!
3.1 Baking phases
The decisive advantages of baking with STIR®(increase in volume, faster gelatinisation of
the starch, faster formation of the crumb, attainment of the core temperature) are reached in
the first baking phase. The hereby saved time significantly determines the overall baking
time.
3.2 Humidity
STIR®is particularly effective for damp surfaces as well as damp and cool dough’s
respectively masses. Thus the following facts are applied:
Refining at low temperatures offers an additionally advantage in quality.
With full steam the STIR®-effect can apply at its best.
Let out the steam from the pastries on time, in order that a better crumb structure will
be developed.
3.3 Mellowness
Usual baking times
Preferably cooler mellowness better condensation of steam
Deferment of the mellowness increases the stabilisation as well as development of
aromas and flavours
3.4 Temperature
Do not worry about high heater temperatures in the first baking phase. This applies in
accordance to the respective type of oven, the type of pastries as well as the personal goal.
Rule:
Increase previously applied baking temperatures about 30°C
Hold high baking temperature approx. 3 times longer, e. g. brown bread instead of
previously 5 min, now 15-18 min
3.5 Temperature measurement
In ovens on the basis of domestic gas or domestic fuel oil, the flue gas temperature is
usually measured inside the radiator. This measured value is quite compatible with the
heater temperature (coated surface of the radiator). Here a rapid increase of the

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temperature in the range of 7 to 8°C per minute by increasing the required temperature can
be determined. This is an essential feature of STIR®.
In ovens on the basis of electric energy the temperature sensor is placed inside the baking
chamber. Thus it measures rather the air temperature inside the oven and therewith only
indirectly the temperature of the heater itself. The increasing of the temperature is more inert
and is lying in the range of 5 to 6 degree Celsius per minute.
3.6 Stick out- and flow temperature
This temperature must be set sufficiently low! Too long and too high temperatures are not
only bad for the energy standard but also forcing too high air temperatures, which enforce a
too quick formation of the skin and the crumb.
Attention: Do not select temperatures too low, as the cooktop may have sparsely heat
storage.
3.7 Early skin formation and incrustation
This causes two barriers for STIR®:
1) STIR®cannot infiltrate up to 10 mm into the core of the dough as usual and therewith
cause a faster up warming of the core. This process is slowed down by this thermal
“protective shield”.
2) The increase in volume can be unfolded worse. The skin formation and incrustation acts
like a mechanical “corset”. If the surface of the raw dough piece stays elastic for a longer
time period, an increase in volume of up to 10% in comparison to classic baking can be
reached. Furthermore you can bargain on an equally bubble distribution over the
complete cross-section (otherwise concentration below the crumb).
3.8 Increase in temperature
To ensure a sufficiently high heater temperature after loading, we recommend adjusting
temperature already 10 to 5 min beforehand.
3.9 Short pre-streaming
Before loading the following points shall be achieved:
Deflating of the first hot steam to ensure that preferably quick condensed wet steam
will settle on the surface of the bakery product in the subsequent phase of steaming
Further cooling of the oven atmosphere to minimize the early skin formation
3.10 Steaming
Like strong steaming after loading.
In connection with the above mentioned pre-steaming, a wet steam is brought here, which
condensates well on the surface of the bakery product. Thus STIR®offers a good
absorption. The clearly wet surface is a favourable condition for better energy input.

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3.11 Core temperature
The early achievement of the core temperature and thus the finishing of the first baking
phase with starch agglutination and formation of the crumb is the core of baking with STIR®.
With optimal dampness (dough, surface) and heater temperature, this phase can be
achieved 2- to 4-times quicker in comparison to conventional baking. As soon as the surface
is well browned, the bakery good is well baked through.
3.12 Shut down
The heater temperature should only be decreased again in continuation of the baking
process, if the required core temperature TK of 97°C has been achieved or will be achieved
shortly.
The early shut down will stop the quick increasing. The heater will become a “cooling
absorber” – the STIR®-effect is gone. In the example a shut down to 210°C is
recommended.
3.13 Incrustation
This second baking phase is less the matter of STIR®, but more the task of convection
baking with warm and rather dry air in the oven chamber. Thick crumbs require a longer
time for this baking phase as well as less dampness and sufficient high air temperatures.
Regarding the last point, the temperature can be increased again briefly in the end.
3.14 Steam exhaust
Immediately after formation of the crumb, the steam must be thoroughly exhausted! This
benefits the formation of a strong crumb.
3.15 Finishing baking
Removal of the products from the oven. In the period of time reduction in the first phase the
baking with STIR®can be finished earlier in comparison to classic baking.
Faster baking requires more frequent controlling.

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4 Baking programs with STIR®
The following baking programs are to serve as an orientation and should be tested by
yourself on the respective oven type with respective recipe.
4.1 Oven type: deck oven
Crust loaf 600g (baked on baking foil)
Leave to stand temp. 240°C
3-5 min before loading 265°C
Steam pre-steaming before loading/after loading full steaming
10 minutes at 265°C; extractor closed
Core temperature after 4 min 85°C
30 minutes at 210°C; extractor open
40 minutes total (usually classic 50 min)
Plaited chaplet pastries (baked on baking sheet)
Leave to stand temp. 200°C
3-5 min before loading 220-230°C
No steam
10 minutes at 220-230°C; extractor open
10-15 minutes at 200°C; extractor open
20-25 minutes total (usually classic 40 min)
Chocolate marshmallow shells
Leave to stand temp. 220°C
No steam
14 minutes at 250°C; extractor closed
10 minutes total (usually classic 20 min)
Filled pastry, Danish pastries
Leave to stand temp. 220°C
Little steam
5 minutes at 250°C; extractor closed
15 minutes at 250°C; extractor closed
20 minutes total (usually classic 30 min)
Milk roll
Leave to stand temp. 210°C
Steam
12 minutes at 230°C; extractor open
12 minutes total (usually classic 20 min)

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Plaited yeast bun
Leave to stand temp. 210°C
Steam
13 minutes at 230°C; extractor open
13 minutes total (usually classic 22 min)
Croissant
Leave to stand temp. 210°C
No steam
10 minutes bei 230°C; extractor closed
3 minutes bei 230°C; extractor open
13 minutes total (usually classic 22 min)
Chelsea bun with crumbles
Leave to stand temp. 210°C
No steam
16 minutes at 230°C; extractor closed
Thus quick dough browning –crumbles stays juicy
16 minutes total (usually classic 20 min)
Sponged flan base
Leave to stand temp. 200°C
No steam
25 minutes at 225°C; extractor closed
25 minutes total (usually classic 40 min)
Stollen 2000g
Leave to stand temp. 200°C
No steam
65 minutes at 220°C; extractor closed
65 minutes total (usually classic 80 min)
Cheesecake thick
Leave to stand temp. 220°C
No steam
50 minutes at 240°C; extractor closed
50 minutes total (usually classic 70 min)
Brown bread 1000 g (50:50)
Leave to stand temp. 240°C
Steam
1 minute at 280°C; extractor closed
10 minutes at 280°C; extractor open
19 minutes at 220°C; extractor closed
10 minutes at 240°C; extractor open
40 minutes total (usually classic 60 min)

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White bread 1000 g
Leave to stand temp. 220°C
Steam
1 minute at 240°C; extractor closed
10 minutes at 240°C; extractor open
9 minutes at 220°C; extractor closed
5-10 minutes at 240°C; extractor open
25-30 minutes total (usually classic 45 min)
Ciabatta round loaf 1000 g (baked on baking foil)
Leave to stand temp. 260°C
3-5 min before loading 290°C
Steam pre-steaming before loading/after loading full steaming
15 minutes at 290°C; extractor closed
Core temperature after 15 min 94°C (usually classic 74°C)
20 minutes at 210°C; extractor open
10 minutes at 260°C; extractor open
45 minutes total (usually classic 60 min)
Split rolls 60g (1x15 pcs.)
Leave to stand temp. upper heat 240°C/lower heat 230°C
Steam carefully several times after loading
5 minutes upper heat 260°C/lower heat 220°C; extractor open
5,5 minutes upper heat 230°C/lower heat 220°C; extractor closed
2,5 minutes upper heat 215°C/lower heat 220°C; extractor open
13 minutes total
Energy consumption (only baking): 480Wh
Rolls (2x15 pcs.)
Leave to stand temp. upper heat/lower heat 240°C
Steam 2x5 s
3 minutes upper heat 250°C/lower heat 250°C; extractor open
5 minutes upper heat 230°C/lower heat 230°C; extractor closed
6 minutes upper heat 215°C/lower heat 220°C; extractor closed
14 minutes total

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4.2 Oven type: baking oven
Rolls 60 g (120 pcs. baked free on base plate)
Leave to stand temp. upper heat 240°C/lower heat 215°C
Steam 12 s/10 s pause/again 5 s
3 minutes upper heat 225 °C/lower heat 215 °C
10 minutes upper heat 235 °C/lower heat 215 °C
13 minutes total
4.3 Oven type: STIR®-tunnel oven
1
2
3
4
5
6
7
8
9
10
Zone
1
2
3
4
5
6
7
8
9
10
Baking time
[min]
4
8
12
16
20
24
28
32
36
40
Oven length [m]
Steam
STIR®
Convection
Energy type
170
450
550
450
350
340
330
320
310
300
heater [T]
170
190
210
240
270
260
250
240
230
220
Baking
chamber [T]
5 Comparison of energy consumption with STIR® vs.
classic baking oven
Source: IGV (Institut für Getreideverarbeitung GmbH), Bergholz-Rehbrücke
Comments:
Baking of 1000 g raw dough pieces (converted from weight for 30 raw dough pieces,
1800 g)
Rolls, initial mass weight á 60 g
The energy values refer to the total baking process.
The energy values are average values.
Deck oven
classic
Deck oven STIR®
Energy consumption per kg
initial mass weight [Wh]
550
450
Energy saving [%]
18
Baking time [min]
17
13
Time saving [%]
26

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6 Comparison of furnace practice with STIR®vs. classic
baking oven
Short pastry –whole meal –biscuit (deck oven)
Classic
STIR®
Upper heat
220°C
280°C
Lower heat
220°C
230°C
Dough weight
13,4 g
Baking time
15 min
7 min
Baking losses
14 %
11 %
Whole-wheat-bread (deck oven)
Classic
STIR®
Upper heat
230°C → 210°C
200°C → 260°C → 210°C
Lower heat
230°C → 220°C
230°C → 200°C
Dough weight
1050 g
Baking time
50 min
35 min
Baking losses
13,3 %
11,4 %
Wheat rolls (deck oven)
Classic
STIR®
Upper heat
230°C
250°C → 230°C → 215°C
Lower heat
230°C
250°C → 230°C → 220°C
Dough weight
55 g
Baking time
20 min
14 min
Ciabatta (deck oven)
Classic
STIR®
Upper heat
235°C → 225°C
250°C → 270°C → 240°C
Lower heat
225°C → 215°C
240°C → 260°C → 240°C
Dough weight
300 g
Baking time
34 min
28 min