GEA has introduced the CookStar First, a twin-zone spiral oven aimed at small to mid-sized food production operations. The new unit extends the existing CookStar product family and is designed to deliver consistent thermal processing for a range of applications including coated poultry, plant-based foods, steam-cooked products, and ready meals.

Thermal uniformity and throughput

The CookStar First uses a twin-zone spiral configuration with integrated booster impingement, combining horizontal and vertical airflow to improve heat transfer uniformity across the conveyor belt. GEA reports that core temperature variation across the belt is limited to approximately 1°C, compared with deviations of up to 6°C in conventional ovens. This tighter thermal control enables cooking time reductions of 10-30% whilst maintaining consistent product colour and internal doneness. The system can achieve throughput of up to 1,700 kg per hour, with yield improvements of up to 3% attributed to more stable processing conditions.

Diagram of airflow in GEA’s CookStar First oven

Energy and water efficiency

A key design focus for the CookStar First is resource efficiency. GEA engineers introduced an intelligent active exhaust system alongside adjustable product gates to minimise air leakage and maintain consistent internal conditions. Improved water circulation enables water reuse within the system. Collectively, these design features reduce energy and water consumption by up to 12%, and the unit has been awarded GEA’s “Add Better” label, based on independently validated performance criteria.

Process control and connectivity

The oven is equipped with the GEA SmartControl human-machine interface (HMI), which provides operators with real-time process data, alarm management, and a 24-hour event timeline for tracking parameter changes. The system is also compatible with GEA Insight Partner technology, supporting remote diagnostics, service intervention, and maintenance planning.

Installation and scalability

With an overall height of less than 3.9 metres, the CookStar First is intended for installation in existing facilities, including brownfield sites with restricted ceiling clearance. The unit shares a common footprint with other models in the CookStar family – including the standard CookStar, which adds smoking functionality, and the CookStar Turbo, which scales capacity to 12,000 kg per hour with roasting capability – allowing integration into existing CookStar production lines.

GEA supports the range with food technologist application expertise, operator training, and a global service organisation covering commissioning through to long-term operational reliability.

For more information, visit: gea.com
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GEA’s CookStar
First twin-zone spiral oven