Project Overview
- Client: A global leader in pet food manufacturing
- Location: Europe
- Equipment: Two dual-fuel forced convection hybrid ovens
- Product Range: Dog treats (biscuits)
- Expected Completion: Summer 2026
Decarbonising Pet Food Manufacturing
Food manufacturing is evolving rapidly, and as the transition to net zero progresses, baked goods manufacturers are seeking low-carbon solutions to implement in their factories. At Spooner, we have a rich history of innovation, continually developing the capabilities of our equipment, including the introduction of hybrid dual-fuel options.
As an industry-leading food manufacturer that is committed to net zero, this client approached us with the task of creating future-proofed ovens for its European factory. The adoption of hybrid dual-fuel ovens contributes to this overarching goal and allows the facility to reduce its gas consumption by utilising on-site solar power generation as a supplementary fuel source.
Project Brief
Our mission was to design, develop, and manufacture two bespoke, state-of-the-art, ovens that would help deliver against corporate sustainability goals, whilst maintaining consistent product output and quality across their range of dog treats.
Each product has different baking requirements and therefore, the two oven solution needed to be carefully designed and engineered to deliver the distinctive baking properties.
This global pet food company chose dual-fuel hybrid over a fully electric oven to facilitate a gradual transition from 100% gas blended gas and electric once the local grid capacity increases and they build their own capacity through solar generation. Implementing a hybrid solution will allow them to adapt over time to both energy supply capacity and pricing.
Custom Hybrid Oven Design
The design phase for these hybrid ovens involved significant innovation and collaboration. Our in-house engineering team led the technical design, closely following the specifications developed from the original sessions.
Through our engineering expertise, our specialists were able to design two ovens that had the capability to seamlessly switch between electric heating and gas-fired heating, accommodating the facility’s renewable energy infrastructure while maintaining production flexibility.
Developing Hybrid Ovens with Engineering Expertise
Our industry-leading hybrid oven systems include a unique electric element that has been specifically designed for Spooner. The unique properties of the electric element mean air flow no longer needs to move left to right and instead can move multi directionally to allow for even distribution across the biscuits, delivering the same baking conditions as a fully gas-fired oven. Our experts controlled and manipulated the airflow to ensure the air was sufficiently mixed to provide the required distribution of temperature and velocity. We had to ensure we kept the same profiles and consistency we’re known for, but with a new heat source added to the mix.
Our hybrid technology has been extensively tested over the two-year development period to achieve performance metrics that outperform what is conventionally available in the market.
Enhanced Manufacturing with Dual-Fuel Ovens
The adoption of these two dual-fuel ovens will introduce a new level of energy efficiency. Every piece of equipment we produce is highly efficient to enable consistent and reliable production, whilst minimising energy consumption. More reliable operation also means less waste and more consistent final products, further enhancing the sustainability profile.
Introducing a dual-fuel capability will ultimately allow the site to utilise the abundant electrical energy supplied by its solar panels, reducing its carbon emissions and energy costs. However, we have engineered a system that would enable them to effortlessly switch between power supplies or utilise both simultaneously with varying compositions between gas and electric when the solar output dips.
Moving Forward
This project is due for installation and commissioning in Summer 2026. By investing in hybrid oven technology now, this international manufacturer positions its facility at the forefront of sustainable pet food manufacturing.
The implementation of our industrial hybrid oven solution will allow them to benefit from significant energy savings across their three product lines. For example, the adoption of this solution is estimated to save them 200kW in natural gas usage per hour, on one production line. These savings will be further amplified when they increase the utilisation of their on-site solar generation in the coming years.
Our hybrid oven solutions have been built with long-term flexibility in mind. The equipment will adapt and grow with the client, depending on any future changes in energy supply, including a possible fully electric transition in the future. Furthermore, we can continue to support the manufacturer with lifetime service and maintenance for their equipment to ensure the ovens continue to operate optimally for years to come.
