Success stories
Electric Steam Generator for IBC Washing Machines
Project Description
An international manufacturer of industrial packaging needed to integrate steam into an IBC and drum washing machine to clean containers effectively, reduce water and chemical usage, and have a replicable, adjustable, and compliant solution to certify its own machine.
Original Situation
What challenges did the client present us with?
The Challenge: Integrating Steam into an IBC Washing Machine
Our client is an international manufacturer of industrial containers that also designs its own machinery. It needed to incorporate a steam generator into one of its machine models for cleaning IBC containers and drums. These containers return from the market after use and must be thoroughly cleaned before being reused.
Steam cleaning of IBCs was key to the process. Without steam, it was impossible to remove the residue adhering to the inside of the containers or reach the temperature necessary for effective cleaning. In addition, steam reduces water and chemical consumption compared to conventional washing, which is essential for a company whose business is based on the circular economy.
The project was not a standalone installation but rather the supply of steam generators for machinery of the same model. This presented challenges specific to an equipment manufacturer:
- Identical and replicable units. The same behavior, the same connections, and the same documentation across all units, allowing them to be integrated in series without having to redesign them each time.
- Adjustable power. Steam demand varies depending on the type of container and the phase of the cycle, so the generator had to modulate its power rather than always operating at maximum capacity.
- Durable materials. All parts in contact with water had to withstand intensive, continuous use without corrosion, since the containers may have held food, chemical, or pharmaceutical products.
- Controlled water quality. The system operates almost continuously and is supplied with municipal water, so it was necessary to prevent scaling and ensure the boiler’s service life.
- Regulatory compliance and complete documentation. The customer had to certify its own machine, so it needed pressure equipment compliant with the European Pressure Equipment Directive, along with electrical and hydraulic schematics for integration.
- Delivery schedules compatible with their manufacturing schedule.
In short, they were looking for a steam supplier that would function as a reliable component within their machine, not as a standalone unit.
Steam solution developed ad hoc by Giconmes
Solution Provided
Steam solution developed ad hoc by Giconmes
Proposed Solution
Giconmes proposed an industrial electric steam generator from its standard line, configured for in-line integration into the customer’s machine: the [NGV-6060](link to product sheet). Three identical units were supplied, each with its own blowdown system and [water treatment](link to water treatment page).
NGV-6060 All-Stainless Steel Steam Generator
Variable power output from 20 to 60 kW, provided by two independently operating 30-kW heating elements. The generator adjusts its power output to the actual demand of each wash cycle.
Steam production of up to 82 kg/h at a temperature of up to 178 °C. The safety valve is set to 7 bar.
All components in contact with water are made of AISI 304 stainless steel. This ensures corrosion resistance during intensive use. It can also be manufactured in AISI 316 if the process requires it.
Fully automatic operation and unlimited runtime. It is powered directly from the mains or from an auxiliary tank.
Compact design: 830 × 830 × 570 mm and 114 kg, easy to integrate next to the machine.
Automatic purge system
A 90-liter stainless steel blowdown tank drains water from the boiler at programmed intervals. This removes concentrated solids and keeps the interior clean without operator intervention.
Water Treatment for the Boiler
A water softener reduces the hardness of the municipal water supply to levels acceptable for the boiler. Given its nearly continuous operation, this step is crucial for preventing scale buildup and extending the service life of the steam generator.
PED Certification and Documentation for the Manufacturer
Each steam generator is manufactured in accordance with the European Pressure Equipment Directive 2014/68/EU (Category III) and the UNE-EN 13445 standard, using steel that is traceable for a minimum of 10 years. Each unit is delivered with:
- CE marking on the boiler
- Electrical and hydraulic diagrams
- instruction manual and maintenance information
With this documentation, the manufacturer can integrate the equipment and certify its own machine without any additional engineering work.
CHALLENGES
We meet our clients’ requirements
Technology Used
- NGV-6060 Full Stainless Steel Industrial Electric Steam Generator, variable power output from 20 to 60 kW, up to 82 kg/h and 7 bar
- Three identical units, designed for series integration, with their own blowdown system
- 90-liter stainless steel blowdown tank
- Water softener for treating municipal water
- Manufactured in accordance with the European Pressure Equipment Directive 2014/68/EU, Category III, and the UNE-EN 13445 standard
CHALLENGES
We meet our clients’ requirements
Easy integration into production lines and certification. The three units are identical in configuration, connections, and documentation, and leave the factory in compliance with pressure equipment regulations. The manufacturer incorporates the steam into each machine as just another component and certifies it without any additional engineering work.
Long service life with minimal maintenance. Stainless steel throughout the water circuit prevents corrosion. Water treatment and automatic blowdowns prevent scale buildup, the leading cause of breakdowns in a steam generator.
Consumption adjusted to demand. The two independent 30-kW groups allow the unit to operate at half power during periods of lower consumption. This reduces electricity costs and wear on the heating elements.
A more sustainable, fuel-free cleaning process. Steam cleaning of IBCs reduces water and chemical consumption. Since it is an electric steam generator, it does not require a boiler room, a chimney, or fuel—all it needs is an electrical and water connection.
Do you need a customized solution?
We help you define what type of installation you need
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:
- Understand and follow the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Do not put the installation into service or allow pressure equipment to operate 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 pressure equipment within the operating limits specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Maintain facilities, pressure equipment, safety accessories, and control devices in accordance with operating conditions and the manufacturer’s instructions, and inspect them at least once a year.
- Arrange for the corresponding periodic inspections to be carried out in accordance with the provisions of 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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USES OF STEAM IN INDUSTRY AND OTHER BUSINESSES
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The use of steam is gaining popularity in various industries due to its effectiveness and environmental benefits.
In our “Success Stories” section, you can learn more about companies that have adopted this technology and achieved successful results in terms of efficiency and sustainability. Click on the success stories to learn more.
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