IN Brief:
- CookStar First is positioned for small to mid-sized processing lines.
- The oven uses twin-zone spiral cooking with booster impingement airflow.
- GEA cites reduced cooking times, tighter temperature control, and resource savings.
GEA has introduced the CookStar First, a compact twin-zone spiral oven designed for small to mid-sized food production lines, expanding its CookStar cooking portfolio with a unit intended to deliver spiral-oven performance in a footprint suitable for constrained plant layouts.
At the core of the CookStar First design is a twin-zone spiral configuration with integrated booster impingement. By combining horizontal and vertical airflow, GEA states the system can deliver more uniform heat transfer across the conveyor belt, limiting core temperature variation across the belt to approximately 1°C, compared with deviations of up to 6°C in conventional systems.
GEA also cites cooking time reductions in the 10% to 30% range, alongside yield improvements of up to 3%, supported by stable thermal conditions and more consistent product heating. Throughput is specified at up to 1,700 kg per hour, positioning the unit for processors that require higher throughput than linear ovens typically deliver, without taking on the building and services work that large spiral systems can require.
The CookStar First’s physical envelope has been configured for installation in existing facilities. GEA lists a total height of under 3.9 metres, with technical specifications including a 47-metre belt length and 600 mm belt width, which aligns the unit with mid-scale product flows rather than high-capacity, multi-metre belt systems.
Energy and water consumption are also a central part of the technical proposition. GEA has incorporated an intelligent active exhaust system, design changes intended to minimise air leakage, and improved water flow to enable reuse. The company states these measures can reduce combined energy and water consumption by up to 12%, depending on operating conditions and product mix.
On controls, CookStar First is supplied with a SmartControl HMI intended to provide process monitoring, alarms, and event timelines, and it can connect to remote diagnostics and maintenance support via GEA’s digital service tools.
The unit is positioned for a broad product set, including steam-cooked items, coated poultry, ready meals, and plant-based formats, reflecting the mixed-product realities of many mid-scale processors. With the system now launched, uptake is likely to track sites looking for tighter thermal control and throughput gains without extending building footprints.
