Heinrich Schulze Ladencafé GmbH upgrades its baking line from contact oiling to spray oiling. The customized solution from technotrans delivers precise dosing and reduces equipment-related downtime to zero.
Producing premium baked goods requires the highest level of precision—especially when traditional recipes meet fluctuating environmental conditions and organic ingredients. To precisely control the adhesion properties of gingerbread and biscuits on the baking belt, Heinrich Schulze Ladencafé GmbH invested in a customized spray oiling system from technotrans SE. The solution replaces a failure-prone contact oiler on a 50-year-old continuous oven and applies the vegetable release agent contact-free and in precisely adjustable quantities. Thanks to the new technology, the traditional bakery manufacturer benefits from product changeovers within seconds, significantly improved hygiene, and a reduction in equipment-related downtime from up to 20 hours per year to zero.
Located on the edge of the Teutoburger Wald, Heinrich Schulze Ladencafé GmbH has combined artisanal baking expertise with industrial production capabilities since its founding in 1830. Now managed in its sixth generation by Arne Knaust, the family-owned company produces a broad range of biscuits and gingerbread products—from handcrafted batches of just 30 kilograms to productions of several tons. One particular challenge in daily operations is the company’s nearly 200-year-old gingerbread recipe. The manufacturer deliberately avoids artificial moisture regulators, making the dough extremely sensitive to climatic conditions. High temperatures and humidity cause the gingerbread to absorb moisture and become sticky, while cool, dry weather leads it to harden quickly.
These natural fluctuations require precise control of the baking process, particularly when applying release agent to the steel belt of the approximately 50-year-old continuous oven. “Our recipe contains no artificial additives whatsoever. Gingerbread consists of more than 50 percent sugar, which constantly interacts with the surrounding environment. That makes consistent production on our equipment extremely demanding,” says Managing Director Arne Knaust. The release agent not only ensures that the baked goods detach from the belt after baking; it also defines the critical adhesion threshold during the baking process. For example, a filled gingerbread heart requires a precisely controlled level of adhesion to prevent it from shifting during automated filling or sticking to the filling nozzle.
Fluctuating Raw Material Quality Requires Maximum Flexibility
The previous system—a conventional contact oiler that transferred oil to the belt via felt pads—had reached its limits under these demanding conditions. It responded slowly to adjustments and delivered inconsistent dosing volumes. On production days involving up to six product changes between high-fat butter speculoos and nearly fat-free gingerbread blanks, this led to significant challenges.
The raw materials further intensified the situation. The company processes large quantities of Fairtrade and organic sugar sourced from various growing regions in South America and Africa. Depending on the batch, the sugar behaves very differently within the dough. Operators must therefore adjust the release agent immediately and with exceptional precision. “When we notice that a dough suddenly spreads more or adheres less, we have to react instantly. With the old system, we often ended up with either too much oil on the belt, causing products to slide around, or a dry-running belt,” explains Knaust. The result was product waste and annual downtime of 10 to 20 hours.
Contact-Free Media Application Increases Production Reliability
Following a recommendation from within the industry, the manufacturer turned to technotrans SE. The specialist in thermal management and fluid technology analyzed the specific requirements and developed a tailored solution. technotrans engineers integrated a compact, contact-free spray system directly at the return roller of the historic continuous oven. “This location offered the most favorable installation point,” explains Hary Kosciesza, Business Development Manager at technotrans. “By mounting the system at the roller, we were able to position our valves optimally while ensuring completely contact-free operation—a decisive hygiene advantage compared to conventional contact oilers.”
The technotrans system operates with four high-frequency switching valves that evenly apply the release agent across a spray width of 800 millimeters. Because the system functions without any mechanical contact with the baking belt, wear from felt pads or brushes is eliminated entirely. The unit is supplied via a compact 19.5-liter pressurized vessel. technotrans selected this capacity specifically to match the bakery’s production cycles and media consumption requirements. A sensor continuously monitors the fill level and alerts employees before the tank runs empty—a major improvement over the previous system, which often ran dry unnoticed and gradually compromised product quality.
Faster Response Time: From Zero to Full Output in Five Seconds
The key advantage of the technotrans solution becomes evident in daily production through its rapid response time. When operators adjust the dosing quantity via the intuitive control panel, the system implements the new setting within seconds. “This is a real game changer for us. While other systems require a long transition period before actuators or felt pads adapt, we can adjust the oil volume here virtually from zero to one hundred percent within five seconds and with complete precision,” emphasizes Knaust. Because the spray unit is positioned only 30 to 40 centimeters before the dough deposition point, employees can immediately see and hear the changed valve switching frequency. This direct visual and acoustic feedback provides operators with a high level of confidence when fine-tuning the process.
The results after the first full production season exceeded the manufacturer’s expectations: equipment-related downtime associated with oil application dropped to zero. Contamination of the oil, which had regularly caused production defects in the previous system, has also been eliminated thanks to the closed pressurized-vessel design.
Seamless Integration into a Historic Machine Environment
The bakery manufacturer was equally impressed by the straightforward implementation process. technotrans technicians installed and calibrated the system in a single evening without disrupting daytime production. Thanks to detailed documentation accessible via QR code directly at the machine, employees were able to resolve any questions immediately.
The technotrans solution also aligns perfectly with the philosophy of Heinrich Schulze Ladencafé GmbH. The company intentionally maintains its 60-year-old machinery because analog equipment is easy to maintain and can be repaired quickly by in-house technicians. The new spray system follows the same practical approach: it is easily accessible, mechanically robust, and designed for simple servicing. Should particles ever enter the oil, employees can immediately identify the issue through the spray pattern and clear the affected nozzle with minimal effort. “The fact that the system completed an entire production season without a single malfunction demonstrates the high operational reliability of our technology—even within the demanding environment of such a traditional machine park,” concludes Kosciesza.
The technotrans system also proved its flexibility during a recent modernization project. When Heinrich Schulze Ladencafé GmbH replaced its historic continuous oven with a state-of-the-art new installation, the oven manufacturer seamlessly integrated the existing technotrans solution into the new machine. Since commissioning, the system has operated just as reliably and trouble-free as before. As a result, the traditional bakery can ensure that its historic recipes continue to be produced at optimum quality for decades to come.