In the food industry, microbiological risk is no longer a one-off issue: it is a structural challenge that threatens product safety, operational continuity and regulatory compliance.
Among all pathogens, Listeria monocytogenes stands out for its ability to survive, regenerate and resist even in cold environments. But there is an even more difficult enemy to eradicate: the biofilm, a complex bacterial community that acts as a biological shield highly resistant to traditional chemistry.
As Europe moves towards a regulatory framework where chemical use is restricted and water becomes a strategic resource, plants need solutions that eliminate pathogens without stopping production or compromising food safety.
This article discusses the problem, explains why current methods fail and presents how dry saturated steam technologies – such as Jet System, Brushless and Giconmes mobile equipment –are transforming industrial sanitization.
The real problem is not Listeria: it is the invisible biofilm.
On today’s conveyor belts, most of the contamination does not come from isolated bacteria, but from complex biofilms attached to surfaces, hinges and microcracks. These biofilms:
- They are formed in successive phases.
- They generate a protective matrix (EPS) that neutralizes disinfectants.
- They host mixed communities: Pseudomonas, Acinetobacter and Listeria.
- Resistant to pressurized water, detergents and QACs.
Most critically, the biofilm matrix acts as a “bunker“. Even if the surface appears clean after a chemical cycle, the inner layers survive, repopulating the tape in a matter of hours.
Why traditional chemical methods fail
The wet cleaning (L+D) protocols were designed for flat surfaces, not for modular belts with hundreds of hinges and microcavities. The main failures are:
a) Physical limitation of the disinfectant
The chemicals react with surface organic matter and are inactivated before reaching the core of the biofilm.
b) Impossible topography
Modular tapes ( Intralox type) contain thousands of joints where the surface tension of water prevents penetration.
c) Resistance formation
Listeria can develop tolerance after repeated exposures to sublethal chemicals.
d) Food safety risks
Insufficient rinsing leaves chemical residues regulated by Regulation (EC) 396/2005.
e) Corrosion, humidity and collateral damage
Motors, sensors and belts degrade with constant use of chemicals and hot water.
Europe 2025-2030: towards thermal and chemical-free processes
The European regulatory framework requires companies to drastically reduce
- the use of hazardous chemicals,
- water and energy consumption,
- industrial discharges loaded with COD/BOD,
- and food waste due to cross-contamination.
Under the Green Pact and the Chemicals for Sustainability Strategy, dry steam sanitization is not only a technical advantage: it is a direct response to sustainability requirements, BRCGS/IFS audits and retailers’ “Clean Label” demands.
Chemical vs. steam cleaning at 180 °C: the real comparison
Dry saturated steam operates under thermodynamic principles that chemists simply cannot match:
| Variable | Chemical L+D | Dry steam |
|---|---|---|
| Biofilm removal | Low / variable | High. Instantaneous thermal shock. |
| Water consumption | Very high (15-20 L/min) | Minimum (15-30 L/h) |
| Downtime | High + mandatory drying | Almost nil. Instant dry tape |
| Impact on materials | Corrosion, humidity | Neutral. No chemical attack |
| Occupational Safety | Chemical risk | No chemicals – controlled thermal risk |
| Validation | Human variability | Recordable PLC parameters |
Why does steam work better? Because when it condenses, it releases 2257 kJ/kg of latent energy directly onto the surface, breaking the biofilm matrix and destroying bacteria in milliseconds.
Chemical-free solutions for sanitizing without stopping production
Giconmes has developed specific technologies for each type of belt:
Jet System: for modular belts
- Spinner type impact head.
- Penetrates hinges and cavities.
- Automated cleaning.
- Integrated suction to remove condensate and debris.
- Continuous operation or between shifts.
Brushless: for delicate belts or light debris
- Steam + suction only.
- No physical contact with the band.
- Zero humidity, ideal for bakery.
Brush: for heavy residues
- Mechanical + thermal action.
- Emulsifies fats and doughs in seconds.
RGV series mobile steam equipment
- Up to 10 bar / 185 °C.
- 99% electrical efficiency.
- AISI 316.
- Fast start-up (<10 min).
- Zero plant emissions.
Case study: 70% reduction of microbiological incidents
Industry: frozen dough and pastries.
Critical equipment: 50 m Intralox modular belt.
Initial problems:
- Excessive humidity in the room due to cleaning with water.
- High risk of Listeria and molds.
- Very long cleaning and drying times.
- Corporate water reduction targets not met.
Giconmes implementation:
- Automated Jet System + generator RGV0020.
- Thermal cleaning cycle without pressurized water.
- Direct integration on the line.
Results:
- Biofilm removal and Listeria control without residual moisture.
- Reduction of water consumption >90%.
- Total automation of the process.
- Recovery of productive hours each week.
The future of sanitization is thermal, dry and chemical free
The food industry is at a turning point. Traditional methods are no longer sufficient to ensure safety, sustainability and productivity. Dry steam technologies make it possible:
- eliminate Listeria and biofilm in seconds,
- sanitize without stopping production,
- drastically reduce water, chemicals and spills,
- improve product shelf life and avoid recalls,
- and meet European standards by 2030.
In Giconmes we accompany the companies in this process, offering solutions adapted to their current needs and prepared for the challenges of the future. Contact us and we will help you to design the optimal solution for your installation.