Bühler unveils OptiBake: A game-changer in sustainable wafer production

Global technology leader Bühler Group has introduced a revolutionary advancement in industrial baking with the launch of OptiBake, the world’s first inductively heated wafer oven. This innovation marks a milestone in wafer production by significantly reducing energy consumption, enhancing product quality, and supporting a more sustainable and flexible manufacturing process.

OptiBake stands apart from conventional gas-fired or electric wafer ovens through its innovative use of electric induction heating technology. The system uses electromagnetic fields to generate heat directly in the baking plates, eliminating the need for combustion and significantly cutting emissions. This breakthrough allows up to 50% energy savings, with no direct emissions of CO₂, CO, or NOx. The system not only supports environmental sustainability but also helps manufacturers benefit from reduced energy costs, carbon taxes, and potentially increased subsidies.

“As we developed OptiBake, our mission was to go beyond conventional improvements,” said Sandra Lutz, Head of Business Unit Wafer at Bühler Group. “We aimed to achieve unmatched wafer quality and operational flexibility while providing a tool for our customers to make meaningful contributions to sustainability.”

The environmental impact of the OptiBake oven can be further minimized when operated using low-carbon energy sources, making it an ideal fit for companies working toward decarbonization and energy security. The elimination of natural gas dependency is another step towards resilient and future-ready production lines.

Precision Engineering for Premium Output

OptiBake features a newly designed baking plate system, tailored specifically to work in harmony with induction heating. The technology enables individual control of plate temperatures, ensuring consistent and precise heat distribution. This innovation not only enhances wafer quality but also offers extraordinary responsiveness for recipe changes or fluctuations in production demands.

Inductive heating facilitates precise control and rapid adaptation, optimizing both energy efficiency and product consistency. Additionally, lower baking chamber temperatures reduce wear on components, such as cables and bearings, extending equipment lifespan and lowering maintenance costs. Noise levels are also reduced due to the absence of gas burners, and the system eliminates fire hazards by operating without open flames.

Moreover, OptiBake allows full raw material utilization—burnt scraps are a thing of the past, as the gentle heating process enables the reuse of baking residues. Designed with full electromagnetic compatibility (EMV), the oven seamlessly integrates into industrial environments without interfering with other electronic equipment.

“With increasing pressure from CO₂ regulations, energy cost fluctuations, and evolving consumer expectations, companies need forward-looking solutions,” said Johannes Greil, Head of Product Management Wafer at Bühler. “OptiBake delivers the competitive edge: high quality, enhanced efficiency, and operational agility.”

Industry Recognition and Pilot Partnership

Bühler’s innovation has already received industry recognition, winning the Lower Austrian Innovation Award 2025. Out of 80 submissions and nearly 30 finalists, OptiBake claimed the prestigious Karl Ritter von Ghega Prize, awarded for pioneering industrial innovation. “This award underlines the strength of our innovation and the collaboration behind it,” said Sandra Lutz, emphasizing the teamwork and partnerships that fueled the development.

One such key partner is Loacker, the iconic South Tyrolean confectionery brand known for its premium wafers and chocolate products. Since 2020, Loacker has collaborated with Bühler to pioneer zero-emission wafer production.

“This project aligns perfectly with our family company’s long-term sustainability goals,” said Andreas Loacker, Vice Chairman of the Board. Markus Valersi, Project Manager Engineering at Loacker, added: “OptiBake supports our transition toward zero-emission baking while maintaining our high product standards. It’s a vital step in reducing our environmental footprint.”

Shaping the Future at the Wafer Innovation Center

Bühler’s Wafer Innovation Center in Leobendorf, Austria, continues to be a hub for development and collaboration. As the global leader in industrial wafer production systems, Bühler offers tailored solutions for a diverse range of products, including flat and hollow wafers, wafer snacks, ice cream cones, and more.

At the center, customers can test solutions with Bühler’s experts, refine recipes, and explore energy-efficient technologies like OptiBake. Combined with Bühler’s comprehensive global service in sales, maintenance, and spare parts, the center plays a crucial role in driving progress and excellence in wafer production.