New GEA CookStar 1000 for roast, crispy-coated and smoked products

GEA's CookStar 1000 spiral oven – for quality and efficient inline operations

GEA CookStar 1000
The CookStar 1000 for in-line fully cooked smoked fillets. (image GEA)

On 8 April 2021, the Düsseldorf-based GEA launched its new CookStar 1000 spiral oven for food manufacturers that can roast crispy-coated and smoked products. The new oven is the next generation of technology that has led the market for nearly 30 years. It now has more power, precision, and performance.

The GEA engineers have refined the CookStar 1000 for higher capacity and yield with improved product quality and consistency. The company claims that the new oven has more flexibility and greater efficiency than its earlier models. 

Enhancements allow food processors to dry, steam, cook, roast, and smoke products in the same oven while increasing production, improving product variety and quality, and reduced energy consumption. GEA also claims that it is now the most efficient spiral oven in the market.

More power, less energy consumption

The new CookStar 1000 generates up to 25% more heating capacity than previous versions, with improved heat exchanger technology. The throughput consequently increases by up to 25%. Color and crispiness are also enhanced – all within the same footprint. 

The additional power is tempered for optimal airflow across the entire 1000 mm width of the belt, both horizontally and vertically. This is said to enable more even cooking, resulting in fewer over-cooked products and higher yield. The improved airflow and additional capacity increase overall production efficiency with less energy consumption.

The GEA CookStar 1000 industrial spiral oven offers an improved heat exchanger design and optimized horizontal and vertical airflow. (image GEA)

Greater precision and control

The 3-zone cooking with improved booster impingement and airflow efficiency, combined with a unique patented oven balancing system, opens up completely new opportunities for more precise regulation. The active, intelligent exhaust concept moreover provides better oven control with lower consumption of steam. 

The CookStar maintains the required dewpoint in each cooking chamber independent of external influences. Dewpoints can be set between 45 and 95 degrees Celsius (113 and 203 degrees Fahrenheit) at temperatures ranging from 50 to 250 C (122 to 482 F), as required by the recipe.

The updated, more intuitive, and larger control panel monitors critical parameters improving the operator overview. Smart automation improves the level of precision and its technical availability making the oven less operator-dependent.

GEA CookStar 1000- One for all spiral cooker

GEA claims that the CookStar 1000 is the only spiral cooker on the market that can dry, steam, cook, roast, and smoke products in a single machine. The company says all these processes can take place in-line while giving manufacturers ultimate control over each cooking zone for improved product quality and consistency. Faster and more accurate roasting improves food products that remain juicy on the inside, and breaded products remain crispy.

Smoking in minutes versus hours

Already available for the third-generation GEA CookStar 600, but now also introduced on the CookStar 1000 is the possibility to in-line smoke products. It makes CookStar 1000 the world’s only in-line spiral oven that can introduce freshly generated, purified natural smoke (from market-leading specialists in liquid smoke, such as Kerry and Red Arrow) into its airflow. 

This option opens many opportunities to create a distinct and customized flavor and attractive color while maintaining quality, consistency and meeting extended shelf-life requirements. Smoking time is cut from hours to minutes, enabling manufacturers to expand their portfolio to include fully-cooked, smoked products.

Longer life and less maintenance with Endurlon guiding strips

GEA introduces a new low-friction material for the guiding strips for the CookStar spiral ovens. The material, marketed under the name Endurlon, lasts up to four times longer than Teflon due to harder wearing and better temperature characteristics. Endurlon extends the guiding rails’ service life by as much as four times – significantly reducing maintenance costs while promoting high belt speeds (up to 30meters a minute) for products that require minimal cooking time.

The New GEA CookStar 1000 industrial oven (image GEA)
The New GEA CookStar 1000 industrial oven (image GEA)

The new CookStar 1000 complements GEA equipment for upstream operations such as defrosting, marinating, loading, brine preparation, injection, mixing, forming, coating, and downstream processes, including freezing and packing and oil recovery. A broad portfolio, combined with GEA’s extensive process knowledge, allows manufacturers to configure entire lines from a single source, ensuring absolute consistency across all production parameters.

Visit the digital GEA Spotlight Sessions to learn more about trends and the latest technology innovations!

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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