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GEA, the German engineering group, has expanded its food processing portfolio with the launch of the CookStar First, a new compact spiral oven specifically engineered for small to mid-sized food manufacturers. The launch addresses a critical gap in the market for high-performance cooking technology that fits within the spatial and budgetary constraints of growing production lines.

The CookStar First brings the advanced "twin-zone" spiral technology of GEA’s industrial-scale machines to a format rated for throughputs of up to 1,700 kg per hour. This move allows smaller operators to graduate from batch processing or lower-tech continuous systems to precision spiral cooking.

Precision Engineering: Improving Yield by 3%

A key value proposition for the new unit is its ability to deliver superior thermal consistency. Featuring integrated booster impingement, the oven is designed to ensure uniform heat distribution across the conveyor belt.

According to GEA, this technology limits core temperature variation to approximately 1°C, a significant improvement over conventional systems which can see deviations of up to 6°C. This precision allows manufacturers to cook closer to the minimum safety temperature without overcooking, resulting in:

• Yield Improvements: Up to 3%.

• Faster Throughput: Reduction in cooking times by 10-30%.

Compact Footprint and Versatility

Recognising the infrastructure challenges faced by SMEs, GEA designed the CookStar First with a total height of less than 3.9 meters. This compact profile facilitates installation in facilities with limited ceiling clearance, avoiding the need for costly building modifications.

Despite its size, the oven maintains high versatility, capable of handling diverse product categories including:

• Coated poultry and meat products.

• Plant-based alternatives.

• Steam-cooked and baked items.

• Ready meals.

Sustainability and Digital Integration

The oven has been awarded GEA’s 'Add Better' label, validating its resource efficiency credentials. Through features like an intelligent active exhaust system and adjustable product gates, the unit minimises air leakage and heat loss. Combined with water reuse capabilities, the company reports potential reductions in energy and water consumption of up to 12%.

On the operational side, the machine is integrated with the GEA SmartControl HMI. This interface provides operators with real-time process monitoring, alarm management, and a 24-hour event timeline. It also connects with GEA Insight Partner technology, enabling remote diagnostics and predictive maintenance planning to minimise downtime.

Market Context

The CookStar First sits as the entry-level solution in the wider CookStar range, which includes the original smoking-capable model and the high-capacity CookStar Turbo (12,000 kg/h). By standardising the footprint technology across the tier, GEA offers a scalable pathway for manufacturers seeking to modernise operations with improved product consistency and sustainable resource use.