A systemic approach to bread baking automation based on control object parameterization

Abstract

Current studies on the automation of bread baking processes reveal significant limitations in existing control systems, particularly due to the insufficient consideration of humidity regulation in the steam zone of the baking chamber. While modern systems tend to focus on temperature control, fuel consumption, and conveyor speed, they often overlook the key role of moisture in ensuring high-quality end products. Numerous technical and scientific works propose temperature and process control solutions; however, few provide integrated ap-proaches addressing the heat and humidity balance. There is also limited information available on the practical performance of such systems, especially in terms of adaptability and energy efficiency. The need for intelligent, adaptive, and energy-saving systems remains largely unmet in industrial bakery environments.
This study aims to enhance the effectiveness of the bread baking process by designing a two-level automatic control system. The lower level ensures stable regulation of environmental parameters, while the upper level focuses on optimizing the heat and humidity conditions in the steam zone, accounting for dynamic dough properties and external disturbances.
The paper presents a detailed analysis of the G4-PKhZS-25 tunnel baking oven as the control object. The process is viewed as a complex, multi-parameter system where consistent thermal and humidity conditions are critical. Through system analysis and experimental iden-tification, key influencing parameters are defined and formalized. The proposed two-level structure includes a feedback-based bottom level for stabilization and a model-based top level for optimization. The study develops a parameterized model of the baking process, identifying the critical zones of technological influence. It highlights the influence of steam moisture and temperature on crust formation, dough expansion, and product porosity. Engineering models and simulation approaches are used to validate the proposed control strategy. Emphasis is placed on the stability of quality indicators and energy consumption under varying process con-ditions.
The research concludes that traditional single-layer control systems are insufficient for achieving the desired stability and quality in bread production. The study proposes a two-level control framework where the lower level ensures baseline environmental control and the upper level applies adaptive optimization to maintain optimal heat and humidity conditions in the steam zone. The approach contributes to consistent product quality, energy savings, and reduced defect rates. It also lays the groundwork for future development of intelligent control systems in industrial bakery applications.