Across the global bakery sector, the push toward net zero is becoming increasingly important. As sustainability commitments are growing, investment in low-carbon technologies is also on the rise. However, there are still challenges revolving around industrial decarbonisation that need to be addressed.
Industrial baking depends on continuous energy supply, high-temperature processes, and infrastructure systems hugely reliant on natural gas.
In collaboration with industry leaders, we draw from our latest report, Decarbonising Your Bakery to examine the true feasibility of decarbonising bakery production and how hybrid dual-fuel technologies are creating practical, scalable pathways forward.
The Reality of Decarbonisation in Industrial Baking
For most manufacturers, decarbonisation is not a linear journey. It is constrained by grid access, energy pricing, legacy equipment lifecycles, and the physical limitations of existing facilities. What works for one bakery may not necessarily work for another.
Industrial bakeries are among the most energy-intensive operations in food manufacturing. Transitioning this high level of energy demand requires rethinking both internal production and coordination with wider systems such as national energy grids, making decarbonisation a challenge that extends far beyond the factory floor.
The Challenges and Barriers to Decarbonisation
Industrial bakeries face a multi-dimensional decarbonisation challenge. Whether its equipment lifecycles or infrastructure constraints these factors all create interdependent barriers that cannot be resolved through standalone actions.
High Energy Consumption
High energy use is inherent to industrial baking. Its intensity also varies by product type — frozen, part-baked, or fully baked goods have different heating and cooling profiles.
As the Director at Process Energy, Jim Colston notes:
“The first point of call in tackling high energy consumption is process optimisation. Investigating where inefficiencies lie in a process.”
He further explains that “High energy consumption can be considered more of a challenge than a barrier and is one that bakeries will be more familiar with, often making it a priority when factories develop decarbonisation strategies.”
This is particularly relevant when looking at oven performance as bakery ovens typically operate continuously which over time leads to a gradual decline in efficiency.
Andrew Stead, General Manager at SpoonerPlus, highlights, “Bakery ovens tend to be worked very hard, with bakeries often running them 24/7 with limited stoppages. Therefore, bypassing the regular service and maintenance intervals.”
He further emphasises that “if you don’t maintain, optimise, and keep on top of your ovens, then a buildup can lead to an increase in carbon emissions being produced.”
Therefore, as part of decarbonisation strategies more industrial bakeries need to prioritise adopting enhanced maintenance plans, followed by adopting efficient equipment such as dual-fuel hybrid oven systems when an asset has degraded to the point of inefficiency. For example, we supported a global leader in pet food manufacturing, by designing a dual-fuel hybrid oven system that will drive measurable efficiency improvements by optimising how heat is generated and utilised throughout the baking process to avoid excess energy consumption.
Retrofitting Legacy Facilities
Most bakeries operate in legacy buildings, which often means structural limitations or physical constraints, as older facilities may have limited roof space or outdated pipework and electrical systems. This makes it difficult to install renewable energy solutions or new equipment.
According to Jim Colston, “heritage industrial bakers tend to be based in more traditional locations such as town centres, which can be limiting in terms of adopting certain types of renewable energy or making large-scale alterations to a facility.”
Additionally, wider infrastructure such as access to alternative fuels or sufficient electrical capacity is not always in place. This is where a hybrid, dual-fuel oven technology offers a practical solution.
These systems can operate on gas initially, working within existing constraints, before gradually transitioning to alternative energy sources as infrastructure develops or on-site supply becomes available.
Spiralling Energy Costs
Rising electricity costs, and fuel disparity creates financial barriers to adopting low-carbon technologies. Switching to electric-only systems can quadruple commercial energy bills in the UK, with similar rises in other European regions.
As Simon Rowlatt, Business Development Manager at Spooner explains, “electricity is four times the price of gas in the UK.” He emphasises that “in order to drive change, there needs to be a levelling up of fuel costs and incentives.”
The introduction of ‘electric-ready’ ovens enables cost optimisation by enabling fuel switching based on price and availability. This helps bakeries maintain stable operating costs for the meantime, and transition to lower-carbon electricity supplies in the future when either prices become more competitive or they can generate their own green energy supply.
Equipment Lifecycle
For many bakeries, existing ovens and processing equipment are approaching the end of their operational lifecycle, creating a natural point for investment and upgrade. However, this doesn’t always align with a full transition to fully electric systems.
This creates a challenge of whether to delay investment and risk running inefficient equipment for longer or move forward adopting equipment that will not be fit for purpose in 20 to 30 years’ time. This misalignment slows decarbonisation.
‘Electric-ready’ oven systems provide a practical solution, allowing bakeries to invest at the point of need while avoiding premature commitment to a single energy source.
The Role of Hybrid Oven Technology in Net Zero Bakeries
Decarbonising bakery production requires systems that are not only flexible but also future-ready. Spooner’s hybrid dual-fuel oven technology that is ‘electric-ready’ acts as practical, scalable solution designed to support operational continuity while lowering carbon emissions across diverse bakery production models.
Dual fuel hybrid ovens operate on gas, electricity, or hydrogen blends giving the flexibility to adapt to an evolving energy supply.
Hybrid ovens allow bakeries to decarbonise over time, protecting both production and long-term investment, while providing a pathway toward full net-zero operations.
The Transition to Low-Carbon Baking
By adopting hybrid oven systems, manufacturers can move confidently toward decarbonisation without compromising production or long-term investment security.
To understand how hybrid technologies and flexible energy systems can support your bakery’s transition, download our new practical guide Decarbonising Your Bakery or you can get in touch and speak directly with our team.
