WPL-Story of Success: Oven system Kreitmaier with WP ROTOTHERM Rack oven

Story of Success:
Reduce energy consumption and costs long-term

At Kreitmaier Bakery, waste heat is used to heat a 2,500-liter buffer storage to 80 °C. This heats the heating water for concrete core temperature control to a maximum of 29 °C and meets the hot water demand for the crate washing system, the common rooms, and defrosting the freezers. “I couldn’t even imagine it,” Magdalena Kreitmaier was skeptical at first. “Now I can highly recommend it to every baker.”

WPL-Story of Success: Kreitmaier bakery

In October 2023, a long-held dream came true for Kreitmaier Bakery in Grafing near Munich: The new production facility and administrative building was put into operation. As the managing director and a trained business administrator in the skilled trades sector, she had presented a detailed financial plan, while her spouse, in addition to his role as production manager, had also taken on the role of construction manager and meticulously planned the building services.

The WP RETHERM heat recovery system by Ganzenmüller was integrated into these services, saving energy, costs, and emissions. The company has been a strategic partner of WP BAKERYGROUP since 2024. “We’re passionate about what we do, and the Ganzenmüller family and the team at WP feel the same way – that’s why everything went so smoothly,” comments the 36-year-old, describing the planning and installation of the rack ovens and the heat recovery system.

 

Bäckerei Konditorei Kreitmaier GmbH & Co. KG

Managing Director: Max Kreitmaier, Magdalena Kreitmaier
Establishment: 1880
Employees: 270, of which 55 in production (18 trainees)
Home base: Marktplatz 8, 85567 Grafing, Germany
Production: Am Brucker Feld 1, 85567 Grafing, Germany
Locations: 15
Website: www.baeckerei-kreitmaier.de

 

Since March 2024, the gas boiler used to heat processing and heating water has been turned off. The energy is generated solely from the waste heat produced by four of the five WP ROTHOTHERM rack ovens, the flash freezer, and the fully automatic proofer.

The Kreitmaier Bakery building was designed and constructed in accordance with the KfW 40 standard for low-energy buildings. The specialist planner provided the initial spark during the planning phase. Exchanging ideas with BÄKO encouraged the family to also invest in a heat recovery system and to hire an energy consultant to help with the application for subsidies.

“It is crucial to quickly bring together the building services engineer and the specialized contractors for electrical, plumbing, heating, and refrigeration systems,” says Ulrike Ganzenmüller, identifying the key factor for success. Magdalena Kreitmaier adds another factor for success: “The people at Ganzenmüller and WP know how a bakery operates and how production works.”

Together with her partner, the experts at Ganzenmüller slightly revised the floor plan and adjusted the piping layout to minimize heat loss during transport.

A 22 % subsidy of the additional investment was granted in accordance with the funding criteria in effect at the time; up to 40 % of the measures are eligible for funding. Even without the subsidies, the system would have amortized itself in just 10.7 years; with the subsidies, the payback period is now three and a half years. As a rule, an investment payback period is three to four years.

However, Magdalena Kreitmaier was not only focused on generating heat for hot water production; given the circumstances at the time, she also sought to curb carbon dioxide emissions and, consequently, the costs associated with the steadily rising emissions tax included in the price of gas. As a reminder: In 2022, the price of gas was twice as high as it was before the war in Ukraine.

 

Bäckerei Kreitmaier in Grafing

Energierückgewinnung mit WP RETHERM für Warmwasserversorgung im Betrieb

What's more, the construction of the heat recovery system meant that the remaining waste heat could be vented through a single chimney. Cost savings over the chimneys previously required without a heat recovery system: approximately 30,000 euros. Apart from the investment costs, maintenance and inspection costs are also reduced.

Due to the physical properties involved, the installation of a heat recovery system can recover up to 25 % of the energy used during baking. The development of the heat recovery system involved close collaboration with the oven engineers at WP. Thanks to the intelligent RETHERM PLC control system, there is no need for time-consuming settings for each individual oven, and a controlled oven draft is ensured. Uniform baking results unaffected by weather conditions are thus guaranteed.

Four of the five WP ROTOTHERM rack ovens installed, with a combined output of 328 kW, utilize the waste heat from the flash freezer and the fully automatic proofer. Kreitmaier Bakery operates primarily during daytime hours. 20% of the waste heat is recovered from the refrigeration systems for the blast freezers and fully automatic proofer. It is an effective and low-investment way to also use the waste heat from the refrigeration system.

At Kreitmaier Bakery, waste heat is used to heat a 2,500-liter buffer storage to 80 °C. This heats the heating water for concrete core temperature control to a maximum of 29 °C and meets the hot water demand for the crate washing system, the common rooms, and defrosting the freezers. “I couldn’t even imagine it,” Magdalena Kreitmaier was skeptical at first. “Now I can highly recommend it to every baker.”

Heat recovery

Design: Ganzenmüller
Energy source for ovens: Gas
Energy source for refrigeration system: Gas
CO2 reduction/year: 31.28 metric tons
CO2 reduction/year for the baking ovens: 15.41 metric tons
CO2 reduction/year for the refrigeration system: 15.87 metric tons
Output baking ovens: 328 kW
Cost savings heat recovery: 7,638 euros/year
(reference price 1.16 euros/liter, based on April 2022 calculations)
Cost savings controlled exhaust gas extraction: 3,677 euros/year
Payback period without subsidies: 10.7 years
Payback period with subsidies: 42 months
Buffer storage volume: 2,500 liters
Hot water demand/day: 3,092 liters
Hot water demand/year: 928,007 liters

 

RETHERM Heat recovery system

Function: Heat recovery for energy-efficient oven system

ROTOTHERM Rack oven

Baking area: 10.0 – 13.8 m²
Heated by: oil/gas/electric
Best-quality baking results with high energy efficiency

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