Simulate cooling processes, save energy
BakeTwin computes the exact core temperature curve of every product using a 20-layer FDM model — before it even enters the cooler. HACCP protocols are generated automatically.
The problem: cooling times are estimated, not calculated
Most bakeries set cooling times by experience — too long wastes energy and throughput, too short risks product quality and HACCP compliance.
The solution: FDM cooling simulation with 20 layers
BakeTwin uses the Finite Difference Method (FDM) with 20 product layers. The simulation accounts for belt contact resistance, flip intervals, air temperature, and belt type — and calculates the exact core temperature curve before the product enters the cooler.
What the cooling simulation can do
- 5 cooling modes: PU belt, stainless steel belt, convection, combination, two-room — incl. open-structure metal belt with 15–25% better COP
- Real-time simulation: core temperature curve calculated in under 2 seconds — what-if analysis directly in the browser
- HACCP PDF export: automatic protocol generation with temperature curve, critical control points, and signature field
- Flip interval logic: flip intervals are correctly accounted for in FDM calculations — for precise predictions with flipped products
- Moisture loss: calculation using Lewis analogy and Magnus formula — visualize weight loss through evaporation
- Belt type comparison: direct comparison PU vs. metal belt — open metal structure enables cooling from top and bottom simultaneously
Measurable savings from day one
- 10–20% shorter cooling times
- 15–25% less energy consumption
- Automatic HACCP-compliant protocols
- Immediately usable — no calibration needed
Frequently asked questions
Do I need to connect sensor data for the simulation to work? No. The FDM simulation only requires product parameters (weight, dimensions, dough type) and cooler conditions (air temperature, belt type, cooling time). No sensors, no integration — enter the values and the simulation starts immediately.
How accurate is the core temperature calculation? The FDM method with 20 layers typically achieves ±1–2°C deviation from the actual core temperature curve. Accuracy depends on correct input of material parameters.
Can I use the simulation for HACCP documentation? Yes. BakeTwin exports a PDF report with the calculated temperature curve, critical control points, and a signature field that can be directly integrated into HACCP documentation.
Does the simulation support multiple cooling rooms in sequence? Yes. The two-room mode simulates two consecutive cooling rooms with different temperatures, flip intervals, and humidity — typical for spiral coolers with pre-cooling.