Total Oven Control System (T.O.C)

Banner-Day Total Oven Control (T.O.C.) Systems are custom designed to provide the latest in oven automation, optimization and temperature control. These systems are intended for oven retrofit, upgrade or new oven installations. The results are fully integrated automation, flexibility in oven capability, consistent product quality, lowered utility costs and safety that meets all code requirements.

The system features:

Ignition System
Banner-Day has taken DSI to the next level. Our H-6E model of ignition module allows individual control and testing of each burner independently of the entire system, and provides immediate burner status and alarm history. Combine that with our 'rectification' ignitor and you get a highly reliable ignition system.

Burner Control
Our method of burner control allows the oven to maintain precise zone temperature within approximately ± 2°F of set point. The system achieves a typical 12:1 turndown ratio within each temperature zone. This is achieved by monitoring two variables: zone temperature and zone air header pressure.

PLC Control
The modern PLC makes up the heart of a Banner-Day T.O.C. system. The use of a PLC enables complete control of all aspects of the oven – from controlling oven mechanics to providing precise temperature control.

Automation
This includes all aspects of oven automation – main drive, loader, un-loader, all in-feed and exit conveyors, along with fans and coloraiders. Synchronizer systems are replaced with state-of-the-art variable frequency drives and encoders to provide precise and flexible control.

Touchscreen/HMI
The system utilizes the latest color touch-screen HMI as the primary operator interface. This allows quick, easy access to all oven functions from a central location. This interface hosts recipe control, and displays trending of various oven-operating conditions and history.

Gas Train
Our patented Power Interruption Protection (PIP^®) Gas Train provides protection from power outages of 8 seconds or less, thus re-purge is not required.

BENEFITS

Consistent Quality
By combining recipe control, burner control and automation control, a Banner- Day T.O.C. system will create a uniform quality product. All parameters of the oven are controlled directly by the PLC, thus limiting the operator's ability to make oven adjustments based on personal interpretation of the baking process.

Safety
With a T.O.C. system, the oven will meet all applicable safety codes, including OSHA, NFPA 86, Factory Mutual, etc.

Lower Utility Costs
With T.O.C., comes energy savings, especially if the oven is equipped with a constant spark ignition system. Savings in the range of 22% for natural gas and 100 Watts of electricity per burner can be expected.

Full Automation
A T.O.C. arrangement integrates all oven components and function into one centrally controlled and monitored system, allowing operators to quickly start up and run the oven successfully. In turn, maintenance tasks will take less time to perform. Gone are the days of manual adjustments and temperamental oven responses.

Precise Temperature Control
T.O.C. achieves precise temperature by use of two variables: zone temperature and zone air header pressure, thus maintaining zone temperatures within approximately ± 2°F of set point. This allows a turndown ratio of approximately 12:1. Most other systems on the market allow for only an effective 3:1 or 4:1 turndown, and temperature is typically the only variable used.

Another benefit of this control scheme is the ability to recover desired temperatures rapidly. Undesired conditions of flash heat caused by breaks in the oven, and the temperature sag created when the product load returns are virtually eliminated.

Flexibility
With today's demands for constant changes, Banner-Day's T.O.C. provides the ultimate in flexibility. If the oven is mechanically capable of doing it, this system provides unrestricted potential.

For more information, contact us.