Success stories
Goodbye to Manual Cleaning: Automated Steam Cleaning for a Conveyor Belt in the Chocolate Industry
Project description
A chocolate manufacturer needed to automate the cleaning of a nearly 50-meter-long belt conveyor, where cocoa, chocolate, and fat residues adhered tightly and were difficult to remove.
Original situation:
Challenges posed by the client:
A manufacturer of chocolate and cocoa products had a very long belt conveyor (about 50 meters) at its plant, and cleaning it was one of the most demanding tasks in the process.
Chocolate, cocoa, and fat residues stick firmly to the tarp and, once cooled, form a compact layer that is difficult to remove.
The problem lay in the method: each cleaning operation required two workers to spend several hours on a manual, tedious task with variable results, compounded by the line downtime.
The customer presented us with a clear challenge: to fully automate the cleaning of the conveyor, freeing up their staff, reducing downtime, and ensuring consistent and repeatable results in every cycle.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
Giconmes proposed its Brushless system to the client—an automated cleaning system designed specifically for belt conveyors that completely eliminates the need for manual intervention.
The operating principle is simple and effective: the machine distributes steam evenly across the entire width of the conveyor belt through a conveyor that carries away the residue, cleaning and disinfecting the surface in a single pass.
The process is cumulative —the belt becomes cleaner with each cycle—and, since it uses only steam, no chemicals are required: the heat alone removes stubborn grease and reduces the presence of bacteria, yeast, and mold.
A built-in vacuum automatically removes loose debris and moisture, leaving the belt dry and ready for immediate use after cleaning, with no downtime.
In this case, the system was completed with a 20-kW RGV0020 mobile steam generator, which powered a straight head adapted to the width of the tarpaulin.
The system is supplied on a tray that slides under the conveyor belt, making it easy to position and install in a matter of minutes. Because it is portable and adjustable, the same unit can be used on other conveyor belts in the plant.
The key technical aspects of this challenge include:
- Steam-only cleaning, chemical-free, ideal for removing chocolate, cocoa, and grease residues.
- Minimum water consumption, starting at 13 L/h.
- The tape is dry and ready to use thanks to the built-in vacuum system.
- Portable and quick to install, it can be adapted to virtually any width starting at 300 mm.
Technology used:
- Brushless steam cleaning system designed to automate the cleaning of belt conveyors without manual intervention.
- A full-width steam collector to remove chocolate, cocoa, and fat residues in a single pass.
- Integrated waste and moisture extraction to leave the conveyor belt dry and ready for operation immediately after the cleaning cycle.
- RGV0020 Mobile Steam Generator with a capacity of 20 kW, powering a straight head adapted to the width of the tarpaulin.
- A portable system mounted on a sliding tray that can be installed in minutes under the conveyor belt and adapted to other conveyors in the plant.
- Chemical-free cleaning with low water consumption using only steam, starting at 13 L/h, reducing stubborn grease and microbial load.
CHALLENGES
We meet customer requirements
The installation fully met the objectives set by the client. Among the key results are:
Staff reduction. The task that previously required two workers for several hours is now performed automatically and without supervision. The staff is now available for other, higher-value sanitation tasks.
Consistent and repeatable results. Unlike manual cleaning—which depended on the judgment of each operator—steam is distributed evenly across the entire width of the belt, ensuring the same level of cleanliness in every cycle.
Less line downtime. Faster cleaning cycles and, thanks to the integrated vacuum system, the belt is dry and ready for operation immediately, with no wait time before resuming production.
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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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