EKMAŞ OVEN INTEGRATED SYSTEM TECHNOLOGIES - FEST

The Loading Systems

Manual, semi-automatic and fully automatic loading solutions that make the process of transferring dough into the oven more controlled, safer and more sustainable in bakery production lines.

EKMAŞ loading systems are not only equipment; they are professional production solutions adapted to the production area, built with quality components and designed to operate safely for many years.

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Manual Operation Option
7-inch PLC Screen
Remote Fault Diagnosis
You can review the operating principle of the system, oven-front movements and ease of use in the promotional video.
Custom solution for the production line

Choosing a loading system is not only a matter of capacity

In the oven loading process, the important point is not only transferring dough into the oven. The system must be suitable for the oven structure, hood height, production area layout, operator habits and the long-term goals of the business.

At this point, EKMAŞ does not evaluate manual, semi-automatic and fully automatic systems within a single standard model. In each project, oven-front layout, working height, Dough Flipping Oven Loader dimensions and usage scenario are evaluated together.

The main reasons for choosing these systems are the difficulty of finding qualified personnel, the need for standard product quality, the desire to move away from the physical burden of loading and unloading bread with a peel, energy saving and the goal of producing higher quality products.

  • Adaptable structure according to oven type and production area.
  • The system can be raised after operation to open the front of the oven.
  • Special applications that can rise above the hood in ovens with hoods.
  • Manual or automatic working scenarios according to the usage habits of the business.
  • Ability to achieve more controlled production with fewer personnel.
  • Easier-to-teach operation with less dependence on experience.
  • A more regular loading flow that helps reduce the time the oven door remains open.
IMAGE AREA
General oven-front system view / production line photo
Three different operation levels

Manual, semi-automatic and fully automatic loading systems

Every business has a different production layout and investment expectation. Therefore, system selection should not be evaluated only by automation level; ease of use, service accessibility, manual intervention option, energy efficiency, labor saving, personnel availability and long-term operating safety should be considered together.

✋

Manual Loading

Control is with the operator; the structure is simple and practical

The manual loading system is a practical solution in which the operator directly manages the system. Since there is no waiting time for motorized movement, the operator can respond faster in some directions. Although this does not change daily production capacity on its own, it offers the operator faster and more direct control.

It is suitable for businesses that want a simpler mechanical structure, prefer to keep investment cost balanced or want to maintain operator control in the production line.

  • Provides direct operator control.
  • Offers simple use and easy maintenance.
  • Suitable for small and medium-scale production.
  • Provides practical use during the oven loading process.
⚙️

Semi-Automatic Loading

Electric movement, manual use when required

In semi-automatic systems, the loading platform enters and exits the oven with electric movement. It reduces the physical load on the operator and helps the loading process be carried out in a more controlled way.

In some loading processes that normally require the support of two people, a correctly planned semi-automatic structure can make it possible to perform the job with fewer personnel. Thanks to its ease of use, the system can be learned in a short time without requiring very high experience.

One of the most important differences of these systems is that they offer manual operation in case of a fault or whenever the user requires it. This structure helps prevent production from stopping completely and gives confidence to the business.

  • Provides electric in-out movement.
  • Allows manual use when needed.
  • Reduces the physical load on the operator.
  • Provides labor savings.
  • Offers use with less dependence on experience.
  • Can be controlled with a 7-inch touch PLC screen.
  • Remote fault diagnosis can be performed via internet connection.
▦

Fully Automatic Loading

Multi-axis movement and advanced control

The fully automatic loading system is an advanced system capable of automatically performing up-down, left-right and in-out movements in front of the oven. Especially in high-capacity facilities, it helps make the loading process more planned and repeatable.

In production environments where finding qualified personnel becomes difficult, the system offers the operator a work order that is easier to manage. Thus, production becomes less dependent on the experience of specific individuals and the quality standard becomes more sustainable.

One of the strongest aspects of the system is that it offers manual operation in addition to automatic operation. This allows the production line to be managed more flexibly during service, maintenance, fault or special usage situations.

  • Provides automatic up-down, left-right and in-out movements.
  • Offers manual operation support when needed.
  • When the system completes its job, it can be raised to open the front of the oven.
  • Contributes to managing production with fewer personnel.
  • Helps reduce the need for loading and unloading with a peel.
  • Operation counts can be monitored through the 7-inch PLC screen.
  • Remote fault diagnosis can be performed via internet connection.
System visuals

Examples of manual, semi-automatic and fully automatic systems

MANUAL SYSTEM IMAGE
Manual operation in front of the oven

Manual Loading

SEMI-AUTOMATIC IMAGE
Electric in-out movement

Semi-Automatic

FULLY AUTOMATIC IMAGE
Multi-axis movement system

Fully Automatic

Fully compatible system

Using the Dough Flipping Oven Loader together with the loading system

When the Dough Flipping Oven Loader and the Loading System are planned together, the process from fermentation to the oven works with a single system logic. More standard products, more regular production and lower labor requirements are achieved.

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Compatible system approach

Using the Dough Flipping Oven Loader together with the loading system

EKMAŞ loading systems are designed not only as equipment that carries products into the oven, but also as a solution that supports the entire production line. One of the important parts of this approach is the Dough Flipping Oven Loader.

Patented solution

A more controlled fermentation process with the Dough Flipping Oven Loader

The Dough Flipping Oven Loader enables dough pieces to be flipped simultaneously and in a controlled way after fermentation. This prevents time differences between dough pieces and maintains standardization in production.

Especially in businesses with intensive production, flipping dough pieces one by one by hand is both time-consuming and quality-sensitive. With the Dough Flipping Oven Loader, this process is completed in a single movement, providing a more balanced production flow.

  • Allows dough pieces to be flipped simultaneously.
  • Eliminates time differences in the fermentation process.
  • Helps preserve the dough structure.
  • Contributes to a more homogeneous appearance and internal structure in products.
Advantage of combined use

Fully compatible operation with the loading system

The loading systems developed by EKMAŞ are manufactured to work in harmony with the Dough Flipping Oven Loader. In this way, the process from dough preparation to oven loading becomes more regular and professional.

Many users state that when the Dough Flipping Oven Loader is used together with the loading system, production progresses more smoothly, cleanly and under better control.

  • Provides mechanically compatible operation with the loading system.
  • Organizes the production flow from start to finish.
  • Helps reduce labor load.
  • Creates a more stable and repeatable production process.
Note: The Dough Flipping Oven Loader is a patented solution owned by EKMAŞ. When planned together with the loading system, higher efficiency is achieved. If needed, it can also be added to the system at a later stage and used without making any changes to the existing loading system.
Who is it suitable for?

Which businesses benefit more from this system?

The loading system can be considered not only for high-capacity facilities, but also for all businesses that want to standardize production quality, reduce personnel workload and professionalize the working order in front of the oven.

👷

Businesses struggling to find qualified personnel

It makes the production process easier to manage by reducing dependence on the manual skill of experienced personnel.

🎯

Those who want to maintain product standards

A more controlled loading process helps reduce quality differences between products.

🥖

Those who want to reduce peel-based workload

It reduces the physical difficulty of loading and unloading with a peel and provides a more modern working order.

🏭

Those aiming for more professional production

It organizes oven-front operations and creates a cleaner, more controlled and more corporate production flow.

Choosing the right system matters

Which option is more suitable for your business: manual, semi-automatic or fully automatic?

The most suitable solution can be recommended after evaluating your oven structure, daily production volume and current personnel organization.

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Efficiency and quality

Strong contribution in terms of energy, labor and product standard

Loading systems do not only provide operator comfort in bakery production. Thanks to a more regular loading flow, they help reduce the time the oven door remains open, contributing to energy savings.

At the same time, they increase standardization in the production process. In today’s environment where finding qualified personnel is becoming more difficult, easy-to-use systems make production less dependent on the skill of specific individuals. This provides the business with a more sustainable and more controlled production order.

⚡

Contribution to energy savings

A more regular loading flow helps reduce the time the oven door remains open.

👥

Labor savings

Some processes that normally require two people can become manageable with fewer personnel.

🎯

Standard production

Production becomes less dependent on the experience of specific individuals and product standards are maintained.

🥖

Higher quality products

Tiring peel-based operations are reduced and the product is transferred into the oven in a more controlled way.

The EKMAŞ Difference

A special structure that does not stop production or block the oven front

In semi-automatic and fully automatic systems, offering automation alone is not enough. In real production environments, critical details such as service, maintenance, faults and area usage must be considered.

✋

Manual operation support

Semi-automatic or fully automatic systems offer manual operation when needed. This structure is an important advantage for production safety.

⬆️

The oven front can be fully opened

At the end of operation, the system can be raised to the highest point of the oven. This keeps the oven-front working area open.

🏭

Compatibility with ovens with hoods

In ovens with hoods, the system can be engineered to rise above the hood.

🌐

Remote fault diagnosis

In internet-connected systems, remote control and preliminary diagnosis can be performed in case of faults.

Visual presentation area

System details

General view of the system in front of the oven, raised position, oven entry-exit mechanism, rail/trolley details and PLC screen

LARGE IMAGE AREA
General view of the fully automatic system in front of the oven
IMAGE AREA
System raised / oven front open position
IMAGE AREA
7-inch PLC screen / control panel detail
Plan the production flow together

When the loading system and the Dough Flipping Oven Loader are evaluated together, the production line operates in a more integrated way.

When flipping the dough after fermentation, transferring it to the oven and loading it are considered within the same system logic, the business gains a more regular, more standardized and more sustainable production structure.

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IMAGE AREA
Detail photo of rails, trolleys and mechanical components
Quality components

Durable component selection suitable for bakery environments

The components used in loading systems are selected not only for movement capability, but also for reliable long-term operation under the demanding conditions of bakery environments. In floury, hot and intensive production areas, component quality directly affects system life.

STAF brand components used in rails and trolleys are preferred for their structure suitable for heavy working conditions. Since this type of rail and trolley system is designed to operate even in difficult environments such as mud, it provides high reliability against flour-related and intensive-use stresses in bakeries.

  • High-quality rail and trolley components.
  • Structure suitable for floury and intensive working conditions in bakery environments.
  • Mechanical design aimed at long service life.
  • Quality component selection that supports service and maintenance processes.
Why EKMAŞ?

Not just a machine, but an engineering solution adapted to the production process

EKMAŞ loading systems are developed with patented solutions, quality component selection, manual and automatic operation flexibility, an expandable structure and a project-based approach tailored to the production area.

🧩

Expandable structure after installation

Even if the need for a Dough Flipping Oven Loader arises years after purchasing the loading system, the system is planned to work compatibly.

✋

Manual + automatic flexibility

Semi-automatic and fully automatic systems offer manual operation support when needed.

🔩

Quality component selection

Rails, trolleys and mechanical parts are selected to suit bakery environments and target long service life.

🌍

Corporate manufacturing experience

EKMAŞ is an experienced manufacturer that develops solutions suitable for different production capacities and different oven structures.

One of the points users value most is that the system can adapt not only to today’s needs, but also to the future production plans of the business.
Control and monitoring

More conscious operation with a 7-inch touch PLC screen

The 7-inch touch PLC screen used in semi-automatic and fully automatic systems gives the operator the ability to manage the system more easily and monitor operating information.

🖥️

Touch control

The operator can manage the system through a clear and practical screen.

📊

Operation count monitoring

Daily or monthly system operation counts can be viewed on the screen.

🔧

Preliminary fault diagnosis

System information enables faster assessment in fault situations.

🌍

Internet connection

Remote control and fault diagnosis support can be provided in connected systems.

Comparison

Which system is suitable for which type of use?

The table below has been prepared to make the selection process easier. The aim here is not to highlight any particular system, but to evaluate the right solution according to the needs of the business.

Feature Manual Loading Semi-Automatic Loading Fully Automatic Loading
Method of use Operator-controlled manual use Electric in-out movement, manual use when needed Automatic up-down, left-right and in-out movement with manual operation support
Operator physical load Higher Lower Reduced to a minimum level
Manual operation option Standard method of use Can be used in case of fault or need Can be used in case of fault, maintenance or special operation
Oven-front clearance Evaluated according to system structure The oven front can be opened depending on project design The oven front can be fully opened by raising the system
Compatibility with ovens with hoods Evaluated according to the project Can rise above the hood in suitable projects Can rise above the hood in suitable projects
PLC screen Not standard 7-inch touch PLC screen can be used 7-inch touch PLC screen can be used
Remote fault diagnosis Not standard Possible in internet-connected systems Possible in internet-connected systems
Suitable business type Businesses seeking an operator-controlled, simple solution Businesses that want to reduce physical load, use labor efficiently and achieve controlled electric movement Facilities that want automation, monitoring, standard quality and easier-to-manage production
Solution process

Every project is evaluated according to its own production area

For the right result in EKMAŞ loading systems, not only product selection but also the production area, personnel structure, energy efficiency expectations and usage scenario must be analyzed correctly.

1

Oven and area analysis

Oven dimensions, hood structure, working height and oven-front area are evaluated.

2

Usage scenario

The need for manual, semi-automatic or fully automatic operation is determined.

3

Technical project planning

System movements, safety, PLC control and mechanical structure are planned according to the project.

4

Long-term use

Sustainable operation is targeted with quality components and service accessibility.

Choose the right solution with EKMAŞ

Let’s determine the most suitable loading system for your oven, production area and usage method together.

You can contact EKMAŞ experts to get information about manual, semi-automatic and fully automatic system options, evaluate the right solution for your production line and request a quote.

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Manual Loading System – Operator-Controlled FEST Model

Frequently Asked Questions About FEST Loading Systems

FEST loading systems are professional oven loading solutions that enable dough to be transferred to the oven deck more safely, regularly and under better control with manual, semi-automatic and fully automatic models.

EKMAŞ FEST loading systems are offered in manual, semi-automatic and fully automatic models to meet the needs of different businesses, from small and medium-sized bakeries to high-capacity industrial production facilities. The systems reduce the need for peel loading, speed up production flow, reduce operator workload and make the dough transfer process into the oven more controlled.

How does the manual loading system work?

In the manual FEST system, the operator aligns the dough loading platform with the oven mouth through a mechanical arm or rail mechanism and allows the dough to slide onto the oven deck with a simple movement. The mechanical structure of the system reduces the operator’s physical load and minimizes ergonomic risk movements such as carrying a peel and bending.

Who is the manual FEST system suitable for?

The manual FEST system is a suitable entry model for bakeries with low to medium daily production volume, newly established businesses and bakers who want to gradually transition to automation investment. Compared to a fully automatic system, it helps increase production efficiency with a lower initial investment cost.

What is the difference between a manual loading system and peel loading?

Peel loading requires the operator to carry weight, bend at the correct angle and reach into the oven. The manual FEST system supports a significant part of this load with a mechanical mechanism; the operator only guides the movement. This increases speed and reduces the risk of occupational accidents and musculoskeletal problems.

Which oven sizes is the manual FEST system compatible with?

The manual loading system can be manufactured in different sizes to be compatible with small and medium-sized fixed stone deck ovens and rotary ovens. For the right model selection, the oven mouth width, depth measurement and working area should be evaluated together with the EKMAŞ technical team.

How is the semi-automatic loading system different from the manual system?

In the semi-automatic FEST system, platform movement is motorized; the operator only gives the loading start and positioning confirmation. This structure provides higher speed and less physical effort compared to the manual system. In the manual system, all movement is performed by the operator.

How many loaves per hour can the semi-automatic system load?

The capacity of the semi-automatic FEST system varies depending on oven size, bread form, production layout and operator experience. It offers slightly lower efficiency compared to a fully automatic system, but significantly higher efficiency compared to a manual system. Support can be obtained from the EKMAŞ technical team for capacity calculation.

Is the semi-automatic FEST system compatible with the Dough Flipping Oven Loader?

Yes. The EKMAŞ semi-automatic FEST system is designed to work integrated with the Dough Flipping Oven Loader and dough flipping equipment. This integration reduces the transition time between dough flipping and oven loading and helps the production line progress in a more organized way.

Does the semi-automatic system require maintenance?

Yes. Like every motorized mechanical system, the semi-automatic FEST system requires regular maintenance. Routine maintenance includes periodic inspection of the motor, rails, connection points and moving mechanism parts. EKMAŞ provides maintenance protocol and spare parts support after installation.

How does the fully automatic FEST system work?

In the fully automatic FEST system, the operator defines the loading parameters through the PLC screen. According to this program, the system automatically positions the dough platform, aligns it with the oven mouth and completes the loading process. Active operator intervention is generally required only in cases of program changes or faults.

What is a PLC screen and what does it do in the FEST system?

PLC, meaning Programmable Logic Controller, is the electronic control unit that processes and executes the automation commands of industrial machines. In the FEST fully automatic system, the PLC screen is used to program the loading cycle, monitor real-time status and receive fault warnings. The touch interface allows the operator to manage the system more easily.

How much does the fully automatic system increase production capacity?

The EKMAŞ FEST fully automatic system can increase production capacity by up to 45% compared to the traditional peel loading method. This increase is achieved by shortening loading time, reducing stops caused by operator fatigue and ensuring a more consistent loading cycle.

How many people can operate the fully automatic FEST system?

The fully automatic FEST system is designed to operate at full capacity with a single operator. It provides an important advantage in labor efficiency, especially for businesses with night shifts, limited personnel or high-capacity production requirements.

What are the infrastructure requirements for the fully automatic system?

The fully automatic FEST system requires a suitable electrical connection, sufficient oven-front area for rail installation and an accessible control panel area for the PLC unit. Power requirements and layout needs may vary depending on the model. The EKMAŞ technical team determines all requirements by performing site measurements before installation.

What happens if the fully automatic FEST system has a fault?

The PLC screen gives an instant fault warning and the system automatically switches to a safe stop position. EKMAŞ provides technical support and service after installation. Information about critical spare parts, maintenance plans and remote support can be obtained from the sales team.

How much do FEST loading systems cost?

EKMAŞ FEST loading system prices may vary depending on model type, manual, semi-automatic or fully automatic structure, oven dimensions, rail system details, PLC control requirements and installation needs. EKMAŞ can be contacted for current pricing and a project quotation.

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