Here comes the innovation from EBSmoke: It is based on Delta-T cooking, but thinks ahead. In order to control the course of the core temperature curve as precisely as possible, the delta cooking program has to be structured differently. The program requires three criteria in programming, with which the computer can intervene in the process at any time. For this purpose, an initial and a target value for the treatment and core temperature are required and the process duration is also specified. Using this data, the desired program sequence is calculated by the computer. The delta T for the respective program is determined on the basis of the initial values, i.e. always exactly as large as the user needs. The target values are used to calculate the linear temperature profile for the target core temperature and the parallel room temperature, which only serves as a maximum limit.
We call this Smart Delta Cooking.
When this program runs, the controller designs the cooking process in such a way that the actual value of the core temperature is as close as possible to the calculated target value. This means that the heating is only used when it becomes necessary due to a core temperature that is too low. As the core temperature rises very slowly, as is well known, the heating power is used in cycles in the delta cooking phase in order to really only consume as much energy as is necessary.
Since this program calculates and controls a straight line from the start to the target value for the course of the core temperature, an expected F value can already be calculated when creating it. This gives the user a very high level of production reliability and consistency in quality. Compared to step cooking or Delta-T cooking, it is possible to have lower energy expenditure and less weight loss.
EBSmoke was able to prove with long-term tests that smart delta cooking (differential temperature cooking) saves a lot of energy. For this purpose, the existing control of a 2-car system with low-pressure steam direct heating was replaced with the control from EBSmoke. The existing control ran with a step cooking program. Every night over a period of nine months, between 800 and 900 kg of cooking fat were treated with the new dynamic differential temperature cooking.
Results:
Since this program calculates and controls a straight line from the start to the target value for the course of the core temperature, an expected F value can already be calculated when creating it. This gives the user a very high level of production reliability and consistency in quality. Compared to step cooking or Delta-T cooking, it is possible to have lower energy expenditure and less weight loss.
Due to the desired reliability of the comparative figures, the program was not further optimized during the test series. The chamber that was not built for a dynamic differential temperature program has further optimization potential. Nevertheless, quite striking results can be read from the table. The two most important:
• Energy savings of 27% compared to the original step cooking program.
• Weight loss reduction of 3%, although the injection quantity was already reduced by 2% within the tests.
These results should help to make the unavoidable path via F-value cooking easier to understand. The new cooking program offers enormous potential for saving energy.
