Success stories
Cooling tower sanitization automation
Project description
Automated solution for the cleaning and sanitization of a spiral cooling tower in one of the production lines of a leading bakery company.
Original situation:
Challenges posed by the client:
The customer is a leading bakery company that presented us with a clear technical and operational challenge: to develop and install an automated solution for the cleaning and sanitization of its spiral cooling tower, corresponding to one of the production lines.
This system, essential in the baked product processing chain, had a CIP (Cleaning in Place) system previously installed, but its operation was ineffective in achieving the required levels of hygiene.
The inefficiency of the CIP system forced the team to perform extensive manual cleanings every weekend. These tasks included:
- Partial disassembly of components such as conveyor belts.
- The use of special brushes and tools to remove food residues (such as crumbs or grease).
- The application of industrial detergents.
- And careful rinsing with drinking water at controlled pressure.
This procedure, in addition to being tedious, required the dedication of between 2 and 3 operators for 6 to 8 hours a day.
Aware of the complexity and operational impact of these manual cleanings, Bimbo challenged us with very precise requirements:
- Develop a steam cleaning device capable of effectively sanitizing the entire cooling tower in a maximum of 4 hours.
- Include a collector at the bottom of the system that will suck the waste, thus preventing any contamination of the conveyor return.
- Design an encapsulated installation, in order to minimize steam emission to the environment and avoid humidification problems in the plant.
This challenge involved not only an innovative technical solution, but also an intervention that would respect food safety and hygiene conditions, reduce the operational burden on personnel and improve the efficiency of the cleaning process without compromising the integrity of the existing equipment.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
To solve the technical and operational challenge posed by this company, we designed a highly efficient, encapsulated and static steam cleaning solution, capable of being interchanged between the upper and lower conveyor of the cooling tower, optimizing resources without compromising efficiency and hygiene.
A modular structure was developed that integrates an intensive steam cleaning system with the capacity to completely clean the conveyor in less than 4 hours.
The installation is designed to remain stationary during use, but can be easily disassembled and relocated between the two conveyor levels as required.
The main objective was to minimize manual intervention, avoid vapor dispersion into the environment and ensure that there is no cross-contamination between the different stages of the line.
The main components of the installed system include:
- 5 rotary steam spinners:
- Inject up to 1000 jets per minute.
- Linearly distributed to cover the entire surface of the conveyor.
- Made of lightweight, heat-resistant, easy-to-clean technical plastic discs.
- Each consumes between 12 and 15 kW of steam.
- 60 kW static steam generator:
- Completely made of stainless steel.
- It supplies steam to the five spinners continuously and efficiently.
- Encapsulation structure:
- Frame made of aluminum structural profile.
- Closed by means of methacrylate panels, millimetrically adjusted to the contour of the conveyor.
- Minimizes steam emission to the environment and avoids humidification of the production room.
- Lower waste collector:
- Designed specifically for this project
- Collects solid waste and condensate to prevent contamination of the lower conveyor.
- High capacity water/air suction system:
- Connected to the collector to efficiently suction waste and steam.
- Prevents build-up and maintains continuous cleanliness during and after the process.
Although the system is static during operation, it was designed to be quickly moved between the top and bottom conveyor of the tower. This operational flexibility allows maximizing system utilization without the need to duplicate equipment, thus optimizing the customer’s investment.
Technology used:
- NGV6060 60 kW manufactured with all components in contact with water and stainless steel enclosure
- Dome spinner set
- Collector
- Vacuum cleaner
CHALLENGES
We meet customer requirements
The implementation of the custom-designed steam cleaning system for Bimbo’s cooling tower has resulted in significant operational and economic improvements:
Reduced cleaning time and increased production time: the cleaning process was reduced from 6-8 hours to a maximum of 4 hours, resulting in a minimum savings of 33% in time. This frees up additional production shifts, increasing the operational availability of the line.
Elimination of direct labor: previously, cleaning required 2 to 3 operators every weekend. With the automated system, the need for manual intervention is completely eliminated, freeing up human resources for higher value-added tasks.
Elimination of the use of chemical products: detergents or chemical products are completely dispensed with, reducing:
- Environmental impact.
- Handling of hazardous substances.
- The cost associated with their purchase and storage.
Reduced water consumption: by using steam instead of pressurized water, water consumption has been reduced by more than 90%. This has a double positive effect: lower operating costs and improved environmental sustainability.
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There are no emissions beyond those produced during the electricity production process. Consequently, emissions can be neutral depending on the electricity mix. Electric steam boilers are the present and the future.
Absolutely. In fact, it is recommended to achieve maximum efficiency. There is no problem with remote control as long as it complies with current regulations.
A steam generator is a pressure vessel that, together with the piping network, is subject to regulatory control and complementary technical instructions, according to the regulations published in Royal Decree 809/2021, of September 21. Maintenance is divided into a part that can be easily fulfilled by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying heat to water, it transforms into steam at the boiling point and atmospheric pressure. From there, depending on the required saturation degree of steam for its proper application, we need to increase the pressure to obtain a higher temperature. To change the temperature and saturation degree of steam, we always need to modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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