Benchmark Quality Speculoos with 50% Lower Energy Using a Data-Driven Hybrid Steel Belt Oven
Client
Undisclosed
Country
Belgium
This legacy Belgian biscuit brand, internationally, is recognized for its artisanal speculoos, a crisp, caramelized biscuit delicately spiced and golden baked. With a strong presence in Europe and beyond, the brand maintains rigid product standards across all baking lines, especially in terms of texture, flavour, colour, and consistency.
THE CHALLENGE
To install a new baking oven on their expanded production line, to replicate the exact baking performance of our traditional ovens.
Needed to install a new baking oven on their expanded production line, but with a clear condition: “The new oven must replicate the exact baking performance of our traditional ovens. We cannot compromise the speculoos product quality under any circumstances.” Their key objectives are
- Preserve the unique bake profile of speculoos
- Achieve perfect consistency in caramelization and color
- Lower energy consumption
- Avoid long tuning periods during startup
- Maintain the signature surface and bite achieved using steel belt baking
OUR ENGINEERING APPROACH
Data Before Design
Rather than rely on assumptions, New Era deployed a specialized Data Logger inside there existing ovens to scientifically capture the baking conditions responsible for the perfect speculoos outcome.
We Recorded and analyzed
Zone-wise
temperatures
Heat flux and
distribution patterns
Moisture release rate
and drying curve
Product core
temperature and timing
Airflow, exhaust, and
humidity control
This allowed us to map the exact thermal fingerprint of there speculoos production process.
THE SOLUTION
A Custom Hybrid Steel Belt Oven
bottom heat
enabled radiation & convection
repeatable control
system for moisture control
and bake zone configuration
and low downtime
COMMISSIONING
First Results After Fine-Tuning
Once the oven was installed and fine-tuned to match the data profile
The first production batches delivered benchmark quality speculoos
Color, texture, and flavor matched and exceeded the output of legacy ovens
No additional rework or hardware changes were needed post commissioning
The client declared:
"This is the highest quality speculoos we have ever produced."
ENERGY SAVINGS
A Massive Operational Gain
Beyond quality, the new oven delivered impressive energy efficiency:
50%
lower gas
traditional ovens
Reduced
carbon footprint
of biscuit
Stable
baking
adjustment