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    Increasing Productivity and Reducing Energy Consumption in The Pizza Industry by The Synergetic Combination of Cooking Technologies

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    nicolas
    Increasing Productivity

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    1812122, 13:08, Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol 3 hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 sno 1812122, 13:08, Receved 25.Sentemser 020 | Revises 1 December 2020, Acceptec 10 January 2028 Dor 10.111/pp15286 ORIGINAL ARTICLE Fedrecening and Preservation SENSE WILEY Increasing productivity and reducing energy consumption in the pizza industry by the synergetic combination of cooking technologies David Mastrascusa* Tecnologia de Monterey, Escuela de Ingenieria Cencas, Monterey. México Welt nc ETC Global Innovation, New Port Richey FLUSA Correspondence Jose lgnacio Huertas,Tecnologco de ‘Monterrey, Eset de ngereray Ciencias, ‘ve. Eugenio Garza Sa 2501, Monterey. NL 64848, Meson Ema juertas@tec me Funding information CConseo Nacional de Canela y Tacalog wiewitine 1 | INTRODUCTION | Patricia Vazquez-Villegas'® | José Ignacio Huertas'® | Esther Pérez-Carrillo'® | Alejandro J. Garcia-Cuéllar'® | Roberto Nevarez’ 2 Abstract Currently, there is a growing interest in increasing productivity while reducing energy consumption and emissions of air pollutants in the restaurant industry In this regard, we studied the use of hot air, microwaves, superheated steam, infrared, and magnetic induction, and their combinations for the case of the pizza industry. Pizzas cook in hat air impingement ovens were selected as a base case scenario. The quality proper- ties of the pizeas produced by each technology were determined using instrumental techniques. Energy consumption and CO, emissions were measured as well. Then, we explored the combination of technologies that minimize cooking time and found that it can be reduced by 50% when using infrared in the last stage of the cooking process in hot air impingement ovens. This combination of cooking methods reduces the 27% energy consumption and 27.1% of the CO, emissions while retaining the desired quality properties of the pizza, Practical applications This work was developed in collaboration with a wellknown international manufac- turer of cooking equipment. This company, like several other communities, is aware that due to environmental and economic problems, the development of cleaner and more efficient technologies is urgent. However, most of the time, changes in any cooking equipment are related to changes in the quality of the final product. Thus, beyond the need for guiding principles to measure energy efficiency, there is a need for guidelines to measure product quality. Our work addresses those needs for the case of pizza, which isan international bakery product. Pour-Damanab et al, 2014; Shevade et al, 2019). Studies suggest that the use of ovens assisted by different technologies not only Recent trends to reduce energy waste in the food industry involves searching for more efficient technologies, n the baking industry, considerable reductions in energy use have been attained with the Use of continuous het air impingement ovens (Banooni etal. 2008; IFoo Process Pes, 2075451528, tps/dtorg/10.1111pp.15286 ‘wilyorineibraycomioualipe benefits energy use, but also uniform cooking (Araki et al, 2018; Nicolas et al, 2017; Poteau et al, 2015). Hybrid ovens can save up to 58% in energy consumption and 46% in emissions (Catado & Soares, 2012). However, thelr production process involves import ant difficulties, such as the need for a robust theoretical or empirical ‘model for design optimization, the high assembling costs , and the ©2021 Wikey Periodicals ic. | 1oF9 hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. 20 18 UoRnqnp pur Tzaterano UP mpg saRpNny A o>RpeIRUN AO z ; i a g 1812122, 13:08, 2019 aaa MASTRASCUSA BL WILEY Ritlfaccinomntrowin Ss=s0FSt [IN] “Sins need for multiple analyses of the characteristics of the food pro: duced by them (Elezie et al, 2017; Schenkel et al, 2013). Product uality influences the customers’ demand, which makes it the starting point for any comparison between different technologies. However, the evaluation of product quality in the bakery industry hhas been a subjective process. During the baking process, products undergo several heat ig fate depending changes, suchas starch granule gelatinization and disruption, protein solubilization, gluten network formation, gene ation of aroma compounds, and crust browning (Beshes et al, 2016; CGunasekaran, 2016; Papasidero et al, 2016; Putis and Salvador, 2007; Schenk eta, 2013; Wang & Sun, 2008; Zhang et al, 2017) ‘These transformations affect the final cooking and sensory quality of the product. Piza is one ofthe most consumed bakery products Jn the world (Liu etal, 2020), However, there is lack of information regarding the effects of ciferent cooking technologies on their end ‘quality Meanwhile, during the cooking process, the phenomenon with the highest proportion of energy demand (22%-26% of energy con- sumption) is weight loss due toa reduction in water content (Besbes cet al, 2016; Deshlahre et al, 2009: Le-ball etal, 2010), Few studies have been conducted to model the thermal performance of ovens for baking pizzas (Nicolas etal, 2017; Pour-Damanab etal, 2014) or to evaluate the use of thermal vision systems to guarantee product duality (Ma et a, 2014). There is a need for faster cooking methods ‘which can produce uniform cooked pizzas that preserve their cook Ing and sensory qualities. Microwave heating is the most popular and extensively stud Jed emerging technology in food processing worldwide in domestic and industrial applications due to its advantages in heating rates, reduced processing time, easy operation, lower maintenance re- duirements, and reduced use of plant space Tang, 2015), Microwave heating uses electromagnetic waves that propagate inside a cavity {and heat the food by interacting with its polar molecules and fons This heat is propagated by conduction from the center of the food to the surface (Taskrran etal, 2020), The use of microwaves for bake ing products in combination with other technologies has been stud: Jed and reductions in cooking time of up to 75% has been achieved (Sakiyan et al, 2011; Sumnu etal, 2005). The use of infrared (Radiation in food productsin combination ith other technologies has also been extensively studied (Slarikia st al, 2017), It generates a uniform surface heating and produces bread with properties sinilar to those produced by conventional ‘baking in shorter time (Ploteau etal, 2015). The high rate of heating in the form of radiation on the surface of the laaves favors the rapid formation and darkening of the crust. We hypothesize that using IR raiation in the last cooking stage in combination with hot arin the first and second stage will decrease the cooking time, The use of supetheated steam reduces the cooking times be cause its high energy content and condensation on the food surface Induce a high heating rate, which rapily increases the dough tem: perature (Araki et a, 2018; Zzaman et al, 2014). Its effects on bak- ery products ant food drying have been studied. However, there is little information on applications where it is included as part of pizza Dhaking process. It Is hypothesized that by applying superheated steam tothe first stage ofthe bread baking process, the temperature increase will be pronounced reducing the time ofthis stage When using magnetic induction, heating occurs by passing an alternating current through a coil, producing the formation of 2 magnetic field that, when in contact witha ferromagnetic material, generates heat due to the formation of small microcurrents within ‘the material, Heat i transferred from the ferromagnetic material to the food being cooked, The use of magnetic induction technologies is limited for applications in the chemical area such as evaporation of active, radioactive chemicals, and toxic substances in vacuum to ‘produce coatings and nanoparticles (Vllacis eta, 2015). Inthe food ‘industry it has been used, for drying or cooking thin products on ‘ovens with a conveyor belt (-Mashad & Pan, 2017), One ofits main ‘characteristics Is that it has high heating rates despite of this char acteristic, it has been little used for bakery products such as pizza, The objective of this work was to reduce the pizza baking time, and therefore, net energy consumption and CO, emissions, of con- tinuous air impingement (Al) ovens by combining it with microwave (MW) infrared (IR) superheated team (SHS), andmagneticinduction AIND) technologies, while preserving the cooking and quality proper ties ofthe piza. Toward this end, the physical and quality properties ofthe pizza were objectively evaluated and compared against apizze produced by a conventional industrial method. Also, the advantages and disadvantages of each technology were analyzed 2 | METHODOLOGY 21 | Pizza preparation Pizzas of 9 Inches in clameter and 240 g of doush were produced using the following ingredients (flour weight basis): 1,200 g (100%) ‘of wheat flour with 139 protein, 780 gof tap water (65%), 12.96 g of salt (1,089) and 12.96 g of sugar (1.08%), 432 g of instant dry yeast (0.3680, and 36 g of edible vegetable cil (3), The dried ingredients ‘an AZ0OT Hobart Mfg mixer (Troy, USA) a speed level {for 1 min, The oll was added and mixed for 1 min, Finally, the water was added at 25°C and mixed for 2 min, The dough mixture was kneaded for 7 min at level 2 and 3 min at level 3. The dough was ‘weighed and portioned within 30 min after kneading, and the por tons were placed in lightly greased aluminum trays, covered with plastic film, and placed at 4°C for 24 hr. Before cooking, the trays were removed from the refrigerator and left outdoors for 30 min. The dough was spread with a wooden roller and placed in alurninum ‘rays Pizza sauce and Manchego cheese were added as toppings. ‘A commercial air impingement oven (AD was used for cooking the pizzas, To select the reference time and temperature, we run different combinations as described in Supplementary Mate The selected temperature and time were 260°C and 6.5 min. Pizzas produced following this protocol were selected as 2 base case of ‘comparison. hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. ana mo s/enay woH pensumon sy ate SHELL i z i i E : : 2 i 3g ; i i r 5 2 i j 2 a z 1812122, 13:08, MASTRASCUSA=r eee Bei Processing and Preservation Sect Mwy 2.2 | Experimental setup 2.24 | Microwave (MW) The MW experimental setup is shown in Figure 1a.A domestic MW was used in the first cooking stage, and then, the pizza was intro duced into an Al oven. In the MW, the pizza was placed on a plas: tle surface that allowed It ta be removed, and then, trespassed to 2 commercial aluminum tray. This plastic surface was placed on @ turntable that allowed it to rotate ziming to have 2 uniform heating ‘The variables that were modified inthe operation of the MW were power (300 W-600 W) and residence time (10 5-6.5 min} The Al Coven was kept ata constant temperature (287°C), and the time was varied inthe range of 3 min-4:3 min 2.2.2 | Superheated steam (SHS) ‘The schematic SHS application is shown in Figure 1b. A 0.25-inch copper tube, 4.2 m long, bent forming a coil shape, vith one end hermetically sealed, was installed inside the oven cavity. Fifty-one (0.0625-inch holes equally spaced every 1” were made in the last ‘quarter sections of the tube. The tube was preheated with the hot air flowing inside the oven for 40 min, Water was pumped inside the tube using a syringe pump at 3 rate of 8 mV/min-32 mi/ rin. In this way, SHS was produced at the operating oven tem perature. The SHS was applied over the first stage of the baking process at an average temperature of 245°C. Once the pizza was positioned under the tube, the SHS was applied, then, the steam flow stopped. and only the hot air was left during the rest of the cooking time. @ Hot Air Impingement oven Resistance: Induction cooker Hot Air Impingement oven ib 2.2.3 | Magnetic induction (MI) We used a domestic induction stave before introducing the pizza in the Al oven. We also used IR at the end of the baking process (Figure 1c The residence time at the induction stove varied from 415 sto 1.5 min and power from 300 W to 1,000 W. We used a 10” stainless steel 400 series, 31 gauge, circular tray throughout the cooking process. The same levels of operation for IR experiments were used. 2.24 | Infrared (IR) IR technology apalied inside the Al oven is ilustrated in Figure 1d, ‘An incoloy colresistor with a diameter of 6.7 mm, four sections, and {total with of 25.4 cm was used, radiating in te infrared spectrum was placed atthe end ofthe Al oven, aparoximately 10 cm above the pizza surface. The power control of the resistance was done using 2 phase controller. The resistance supply voltage was 220 VAC. For the determination of consumed power, the current was measured with an oscilascope and a current clamp. The valtage was mess lured with a multimeter. The IR power was varied in the range of ‘500 W-2000 WW the air temperature was fied at 315°C, and the band time moved in the range of 2.17 min~6 min. The IRelement was always on throughout the cooking process. 23 | Pizza characterization The final temperature ofthe pizzas was measured with thermocou- ples placed at five random points separated 2" from the edge ofthe ae pump ra 1 Biiial, O) Copper tube UUUUU Hot Air impingement oven ANN uu) Hot Air impingement oven FIGURE 4. Diagram ofthe implemented combinations (a) MW and Al, (b) SHS and Al, (IND. IR, and Al and fd) IR and Al hitpsfifst-oninelibrary-iley-com.ezprony.una. edu. coldollepall10.1111ffpp.15286 Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. ano tno sent woH peptumon sy 28e SHELL i 2 : i E : : 2 | ; i i r 5 2 i i z i a z 1812122, 13:08, 4019 aaa MASTRASCUSA SSWILEY | Ritlfaccino strewn oSs=s0FSt [I] “Svcs pizza and one in the center. The reported value corresponds to the highest temperature taken. The final moisture content was measured by taking slide ofthe pizza and weighting t after carefully removing the sauce and cheese Then, the sample was frozen overnight, and lyophilized for 24 hr at 0.024 mBar. Finally, the freeze-dried sample was weighted again, and Equation 1 was used to calculate the water content, where W, [s the intlal weight of the sample, and W, the final weight of the freeze-dried sample. cy The rapid viscosity testis a technique commonly used in the analysis ofthe properties of starch in bakery products. This instr ‘ment continuously measures the apparent viscosity of the starch bby measuring the torque needed to str at constant speed a mix of starch and water under varying temperature conditions (Sakiyan etal, 2011), The pasting properties ofthe samples were determined using an RVA45O0 Rapid Visco Analyzer (Perkin Elmer, OH, USA). Inthe graph of viscosity versus time delivered in this analysis, the profiles with the highest peak and final viscosity describe a lower degree of cooking, which represents ahgher content of starch gran les that stil nee to be gelatnized. The sample was obtained by arinding the freeze-dried crust with a Cydlone Sample Mill. A 195 solids suspension was agtated continuously at 160 RPM. The heating profile was: keeping the temperature at SO°C for 4 min, heat to 90°C at 15°C/min, keeping the temperature at 90°C for 4 min, cool to 50°C at -15°Cy/min, and keeping at 50°C for 2 min, the STD4 profile was used in ths test, based on AACC Method 76-21.01, ICC Standard No. 162, Data were ‘brained for Windows version 11.2 software. ‘The microstructural properties of the samples were observedinan EVO MA 25 scanning electron microscope (Wu ct al, 2010), Freeze: dried samples of pizza cust of 4 cm? were mounted on aluminum stubs using double-sided tape. The samples were coated with 10 nm (of gold(Q150R Plus - Rotary Pumped Coater, Quorum, UK}, examined under high vacuum conditions and an accelerating voltage of 10 KV. ‘The textural characteristics of the plzze were measured with 2 TAXT plus texture analyser in its extensibility mode of operation (Stable Micro Systems, Godalming, UX). For this, pieces of 15 cm x ‘em werecut and placed in theattachment points ofthe Pizza Tensile Rig attachment (A/PT 5 kg). The test speed was set at 5.0 mm/s, and 2 travel distance of 45 mm, The Exponent software version 6:1.12.0 \was used, and the value of toughness was obtained from the software. For color measuring, the samples were placed in a professional photography set, which consisted of two LED lshts of 30 W each and '5,500 Im intensity (Supplementary Materia. For each photography, the white adjustment was adjusted automatically given the constant lighting conditions and contrast with the background (Zaborowice etal, 2017). The images were processed using Image) software with which the values of color characteristics were abtained in the CIE {eb space for pizza crusts (Yam & Papatdakis, 2004). Since images ‘were acquired in the RGB color space, steps were carried out to obtain CIE L + asbs values, as in (Pulls & Salvadori, 2007). Then, the Browning Index (Bl) was estimated as in (Kurek et al, 2016) (Equations 2 and} X= (0+ 175) /(56451 + a~301b) 2 81 = [100% 031) 017 @ (Changes in cheese color were estimated by a Browning Factor (BF) (Wang & Sun, 2005), This factor is defined (Equation 4) as the ratio between the average sray value of the cheese image before cooking (GV) and after cooking (GV). GV has a range between Oand 255, 0 corresponds to totally black, and 255 to totally white oF Gv/6y, x 100% 4 24 | Energy consumption and CO, emissions ‘These parameters were obtained per pizza and evaluated for each ‘one ofthe combinations. The Energy Consumption (EC, kWh/pizz) EC, was obtained with Equation 5 PG Dia 6 Where PIs the nominal electric power of technology I and tis the time of use of technology ito produce a pizza. In the case ofthe Al oven, time must be multiplied by a.use factor that depends on the ‘temperature ofthe oven Supplementary Material). The CO, emission (EM, kg CO, eq/pizzal was obtained as in Equation 6 based on the emission factor methodology ofthe USEPA (USEPA, 2020), EM, = EFEC, 6 Where EF is the emission factor for CO, emissions per KW of electric energy produced by the national electrical system, the value reported forthe year 2019 was 0,505 kg CO. ea/kWh (CRE, 2020) This factor considers al the different sources for electricity gener ationin Mexico. Emissions Reduction ER 56) was obtained bythe relationship be- ‘ween the CO, emissions per pizza of each technology combination (EM) and the baseline emissions (EM), as shown in Equation 7 (Lv etal, 2021) Ma —EM, fey = Rg cto0) a 2.5 | Statistical data analysis Althe experiments and combinations were caried out by triplicate. Measurements were carried out with a minimum of four random samples per pizza replicate and are presented as their average and hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. sno tno s/eat wo4 peunon sy ate SHELL : z i i E : : 2 i 3g ; i i r 5 2 i j 2 a z 1812122, 13:08, MASTRASCUSAer A standard deviation, An analysis of variance (ANOVA) was used to de termine If there were statistical differences among the values meas red for each property ofthe pizzas with 3 95% confidence interval IMINITAB 18.0 software was used to calculate the significant differ ‘ences by applying the Tukey's method for ap value <.05. 3 | RESULTS (Only 2 few technology combinations produced wellcooked pizzas ina lesser or equal time than the base case of comparison (Table 2). These results ae described below. 3.4 | Pizza's cooking quality attributes ‘The degie® of gelatnization of the starch from pizza samples was Used to corroborate the completion ofthe cooking process (Besbes et al, 2014; Sakiyan etal, 2011) In Figure 2, the viscoamylograms show that samples A through F have less pronounced peaks of Witey-l2%? viscosity and the less pronounced dectease in viscosity in the area next to the peak (specific RVA numbers in Supplementary Materia. They ate corresponding toa good cooking quality pizzaas compared with previous results (unpublished). In the case of samples G (20's ‘on MW combined with 3 min on All, and H (6.5 min only MW), the viscosity peak ishigher as wells the drop in viscosity. Samples G and H are shown only as a comparison to well-cooked pizzas. SEM micrographs of bath samples (Gand H) corraborate the BVA analysis. In Figure 3, micrographs of samples A, G, and H are shown. Figure def show that, in A the starch granules are fully gel tinized and immersed in the continuous gluten network (Della Valle etal, 2012: Le-hal et al, 2010), However, for H, starch granules are stil not gelatinized (Figure 3a 3.2 | Pizza's sensory quality attributes Table 2 summarizes the values for each of the sensory quality char acteristics ofthe produced pizzas. It can be observed thatthe final temperature of the pizzas A to F does not exceed 100°C. G and H TABLE 1 Parameters for each combination of technologies selected in this work Superneated Hot air impingement Infrared steam Induction Microwaves ‘Total cooking ‘Treatment Temperature(°C)Time(min) Power(W) Time(s) Power(W) Time(s) Power(W) Time(3)__tme(in) A 260 650 Z = - z - 650 5 ats 325 1.000, 5 : z 325 c 260 650 13 = 7 = = 650 D 20 650 % 5 « 5 5 650 E ais 300 1.000 - 700 35 - - 358 F 287 4320 : z : 60 4.50 s 287 300 : z - 600 30350 4 : z 5 z 4008050 1200 1000 g Viscosity (Cp) 3 400 FIGURE 2 The sequence of RVA viscoamylograms of bread cooked with Al, 200 MW, IR, IND, and SHS, Letters represent the different combinations (total cooking Al (6.5 min), b) ALR (2.25 min, 0 (cand d) AJ/SHS (6.5 min) fe) AVIND 0 (3.58 min), (9 AUMW (4.5 min) (@) ALM (3.5 min, and th) MWY (6.5 min) 200 400 Time (sec) 800 hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. ano 8 UoRnqnp pur -TzateranoL UP mpg nRpNNH dA OURAN AO z ; i a g 1812122, 13:08, 6o9 =F F20d Mocessing ond Preservation RSS WILEY- Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol MASTRASCUSA sr FIGURE 3. Microsraphs of the bread crumb baked with MW (sample Hi, MW (sample G), and only Al (sample). 300x magnification fora tocand 25x for dtof TABLE 2. Physical characteristics for pizza baked wi Final cooking Combination temperature °C) F 992068 H 5208 ‘combinations have a much lower final temperature than the others The moisture content of sample H, subjected to 6.5 min of MW, is Statistically similar (p > .05) to A, despite having a lower pizza final temperature and a lower degree of cooking. Combinations B and F presented a difference of 3 sd to A. For combination 8 6 nthe final moisture content of the air at 315°C and the lower cooking time) presented a high heating rate im the first and second baking stage when it fs compared with A (air at 260°O. For F, the moisture content was highly influenced by the baking time and air ture (287°C). Although this com ble peak and final viscosities (Figure 2, and final moisture content, crust formation was compromised, as indicated by the BI. C and D had the high ‘the moisture content of the combination E was 6% higher bination presented accent Similar than A. The use of the stainless ste! tray, due tits shape and higher thermal inertia may have retarded its temperature increase inside the hot air oven, which did not allow the pizza temperature to in crease and blocked the water evaporation from its bottom surface. Moisture content ye colar (ab, are not sirificanty th Al, MW, IR, IND, and SHS Toughness Browningindex Browning factor le-sec) 1905 2073 2090 = 2643 ones! 525 20653 2028 2 1523 50.629 191.041.288 2,994 + 102 506+8.20 12872097 1907 + 69a s1s2253 30.5 £2218 1991 22618 a364940 a936 4218 2,204.41058 1092: 7. 1695 + 2640 1682024 4253 202% 1.213 4 164¢ However, this higher moisture content for samples C, D, and E dig the peak viscosity values obtained inthe RVA test nat comaromi Combination G may owe its higher moisture content to the shorter time and air temperature, B and E, which involved the use of IR, had a color similar to Alp > 05) due to the hi manu et al, 2005), Higher IR power may cause a higher Bl ancl a thicker crust, which may affect the other quality parameters neating rate on the product's surface such as texture and starch gelatinization (Sumnu etal, 2005). The combinations C and D, which used SHS in in contrast, showed a lower BI than A. The slight condensation of rst heating sta water at the start of the cooking process is believed to affect ain a darker crust (Bes speed of the reactions nec etal, 20 The texture was similar for combinations B to F compared wit ry to ob s ‘A(p> .05). Combinations G and H hac lower toughness values than nization of cline; this is related to the lower degree of ge the starch, hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 1812122, 13:08, MASTRASCUSAer A TABLE 9. Energy consumption, CO, emission, and cooking time for pizza baked with Al, MW, IR, IND, and SHS ‘oven % redaction of neray consumption Emision (kg CO, e9/Plza) 2% emission reduction Tota cooing tine Energy consumption (kWh Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. ‘Tar Recsdngend recenation EE Wwe” A 8 ¢ Db EF 05200 0.792 Os201 0.5202 OaNeL O.4022 OS KOK HK 02626 01915 02627 02627 02455 02081 00% 272K ON Om SK ETH juction 0% =—«SOK— OOK ASH OK, Note: Bolded values means te technology camlnation with more potential nthe cooking time and energy reauction, 3.3 | Energy, CO, emission, and cooking time Combinations G and H did not produce fully cooked pizzas and were omitted in this analysis. Table 3 presents the results of energy con sumption, CO, emissions, and cooking time. The use of IR (combi ration B) presented the most significant reduction in cooking time ‘anda reduction in energy consumption per pizza. The second higher reduction in energy and emissions s the combination F, which used Wand Al. However, the pizzs produced had an insufficient Bl, and this sa critical quality parameter inthe acceptability of customers. ‘The use of IND, on the contrary, although it represented the second-highest reduction in cooking time with 45%, did not have a considerable impact on the reduction of energy consumption such 1s combinations B and F 4 | DISCUSSION Inthe takeaway food industry, time sa crtical factor. In this regard, \We highlight that i was possible to produce pizzas ina shorter cook ing time and with similar quality to a reference pizza. This reduction in cooking time represents an increase in productivity for cestau- rants, giving them the capacity to produce more pizzas per day, and considerable savings in electric energy bill ‘The use of an Al even in combination with IR and IND technolo- ales reduced 50% of the cooking time while maintaining the quality ofthe pizzas in Al ovens. RVA analysis ofthe pizzas produced using this combination demonstrated that they produced fully cooked piz- 225 with the acceptable formation of the crust. Furthermore, it ex hibited 27% and 271% reduction in energy consumption and CO, emission per pizza, respectively. However, a ferromagnetic tray de sign with minimal thermal inertia is required to take advantage ofthe energy delivered by the magnetic inductor and to improve heating ‘and water migration from inside the pizza. “The use of supetheated steam as part of the cooking process did ‘ot reduce the time or improve the quality of the piza. During the Initial phase ofthe baking process, a water condensation phenome- ‘non on the surface occurred promoting an early crust formation and higher Final moisture content (Pan etal, 2014; Summnu etal, 2005) hitpsifst-oninelibrary-iley-com.ezproxy una. edu, coldol/epell10.1111ffpp. 15286 The use of MW in combination with Al produced pizzas with sim lar properties to the baseline pizza, except for the 2% difference Jn moisture content and a 46% reduction in the BI. Despite these clfferences, the degree of gelatinzation of the starch showed that the pizza was fully cooked. However, MW alone produced pizzas with unacceptable quality characteristics. The rapid temperature increase and moisture removal from the inside ofthe pizza do not allow the completion of starch gelatinization (Sekiyan et al, 2011) Based on these results, we concluded that using microwaves in the first stages negatively affects the product. If the use of MW inside ‘ovens with conveyor belts for restaurants could be solved. it could bbe used to speed up the water removal process in the other stages of the process. The methodology presented in this article estimates the amount of energy savings and CO, emissions reduction for each cooking method. In this work, the evaluation was made for labo- ratory prototypes under specific operating conditions. Although they can maintain the reduction in cooking time, optimization of these designs would further improve the energy and emission re duction performance of the technology combinations. Moreover, this optimization would also allow the pizzas to maintain unifor rity when produced in large volumes in industrial applications and restaurant. In future work, the effect of product size and number willbe studied 5 | STATEMENTS AND DECLARATIONS Research data are not shared. 6 | ETHICS Ethics approval was not requited for this research. ACKNOWLEDGMENTS. This research has received funding from Welbilt (CeCe 0020240133) land the National Council for Science and Technology of Mexico (CONACyT, cvU 948222) ano -uesqauuo-sy'any wor proeetunod 'Sp'L202 “erSPSPLL wero vedo 8 penywied ov AAS RMP PU Hm TeR/2HT Ue eqRPEEL Ka pe RUHNU 1812122, 13:08, Inereasing productivity and reducing energy consumplion in the pizza industry by the synergetic combination of cooking lechnol. 209 aaa MASTRASCUSA ET at SS WILEY| Ritfaccinomntronion S88e0FSC [| “Svcs CONFLICTS OF INTEREST ‘The authors have declared no conflicts of interest for this aril. orcip Patricia Vizavee Viegas © htios//rcd ‘org/0000-0000-1568-4954 José Ignacio Huertas ©) hetps:/orcid.org/0000-0003-4508-6453 Esther Pérez Carlo © nttps:/ored.org/0000-0003-2636-6281 ‘Algandro J. Garci-Cullr @ heepst/rci. .03/0000-0002-3831-7240 REFERENCES ‘Arak, T, Meng. L. Kono, 5. Imamura, H., Ueno, 5. Do, G. & Maeda. 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