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GEA has expanded its CookStar portfolio with a new compact spiral oven aimed at small to mid-sized food manufacturers seeking more efficient and consistent cooking processes.

The CookStar First features a twin-zone spiral design with integrated booster impingement, enabling more uniform heat distribution across the conveyor belt.

The German engineering group says the oven limits core temperature variation to around 1°C, compared with deviations of up to 6°C in conventional systems.

The technology can reduce cooking times by 10-30% and improve yields by up to 3%, according to the company. Throughput is rated at up to 1,700 kg per hour.

Designed for versatility, the oven can handle a range of products, from steam-cooked and baked items to coated poultry, plant-based foods and ready meals.

Its compact footprint, with a total height of less than 3.9 metres, allows installation in existing facilities, including sites with limited ceiling clearance.

Energy efficiency is a key focus for the CookStar First. GEA has incorporated an intelligent active exhaust system, adjustable product gates and improved water flow to reduce air leakage and allow water reuse.

The company reports that these innovations can cut energy and water consumption by up to 12%, earning the oven its 'Add Better' label for resource efficiency.

Operators benefit from digital connectivity through GEA SmartControl HMI, which provides real-time process monitoring, alarm management, and a 24-hour event timeline.

The system also integrates with GEA Insight Partner technology for remote diagnostics, service interventions, and maintenance planning.

The new oven complements the wider CookStar range, which includes the original CookStar with smoking functionality and the high-capacity CookStar Turbo, capable of processing up to 12,000 kg per hour. All models share a common footprint and can be integrated into existing production lines.

GEA provides global support through food technologist expertise, operator training, and service networks to assist with commissioning, process optimisation, and long-term reliability.

CookStar First targets food producers seeking to modernise operations with improved efficiency, product consistency and sustainable resource use – trends increasingly important for manufacturers under pressure to reduce waste, energy use and costs.