Success stories
Thermal disinfection of reusable boxes by means of steam in berry cultivation.
Project description
Steam solution for safe thermal disinfection of reusable boxes in a berry growing plant.
Original situation:
Challenges posed by the client:
A company dedicated to the cultivation of plants for the production of berries needed to ensure a safe, effective and repeatable thermal disinfection process for the reusable plastic boxes (polypropylene) used during cultivation.
The intensive reuse of these containers, together with the high crop density and the raw consumption of the final product, made the disinfection of boxes and trays a critical point in the production process, both from a sanitary and operational point of view.
The customer required a steam-based solution capable of heating an enclosed space of approximately 75 m³ from room temperature to 80-90 °C within a maximum of 2 to 3 hours, in order to introduce the boxes and subject them to heat treatment prior to reuse.
The disinfection of reusable boxes in baby plant cultivation presents specific risks associated with the accumulation of microorganisms on plastic surfaces, where conventional chemical treatments are limited or ineffective.
The customer’s objective was to achieve a complete “biological reset” of the containers before each production cycle, eliminating pathogens without the use of chemicals and integrating the process naturally into daily operations.
The disinfection system should allow the effective elimination of the main pathogens associated with early crop losses, especially those linked to the damping-off phenomenon (seedling drop):
- Fungi and soil pathogens such as Fusarium, Pythium, Phytophthora and Rhizoctonia, responsible for root infections and early crop failure.
- Surface molds and opportunistic microorganisms that compromise product quality and food safety.
- Risks derived from non-homogeneous disinfection in enclosures with a high load of pallets and boxes.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
To meet the thermal and sanitary requirements of the project, Giconmes designed and installed an all-electric steam disinfection solution, sized to ensure homogeneous heating of the cabin and precise control of the process.
The installation was based on:
- 60 kWelectric steam generator, with a production capacity of up to 80 kg/h of steam, sufficient to raise the temperature of the 75 m³ room from ambient to 80-90 °C within the required time frame.
- Four steam injectors strategically distributed in the cabin, ensuring a uniform energy input even at full load, with up to 16 pallets of boxes being processed simultaneously.
- Temperature probe installed at the midpoint of the enclosure, allowing to monitor the actual temperature of the treated volume and to ensure repeatability and traceability of the thermal cycle.
- Destratifier type ceiling fan, in charge of recirculating steam and hot air, avoiding thermal stratifications caused by high space occupation and ensuring a homogeneous disinfection of all the boxes.
Thanks to this configuration, the system guarantees a uniform, controlled and validatable heat treatment, without the use of chemicals and fully aligned with the customer’s food safety and operational efficiency requirements.
Technology used:
- Giconmes 60 kW electric steam generator, made of AISI 304/316 stainless steel, sized for sanitary applications and fully integrated in the thermal disinfection system of the passenger compartment.
- Steam injection system with four strategically distributed injectors, designed to guarantee a homogeneous energy supply even at full load, with up to 16 pallets of boxes being processed simultaneously.
- Temperature probe installed in the middle point of the cabin, which allows monitoring the real temperature of the treated volume, ensuring the repeatability of the thermal cycle and the validation of the process.
- Destratifier type ceiling fan, in charge of recirculating steam and hot air to avoid thermal stratification, especially critical in enclosures with high pallet occupancy.
- Precise thermal control of the process, allowing to raise the temperature of the enclosure of approximately 75 m³ from ambient to 80-90 °C within a maximum of 2 to 3 hours, according to the customer’s sanitary requirements.
- Chemical-free disinfection system, based exclusively on steam heat treatment, aligned with the requirements of food safety, sustainability and daily crop operations.
CHALLENGES
We meet customer requirements
Steam solution to ensure a safe, homogeneous and validatable thermal disinfection process in a berry growing plant. We achieved the following results:
Efficient and repeatable thermal disinfection, thanks to a steam system capable of raising the temperature of a 75 m³ room to 80-90 °C in a controlled manner, ensuring the elimination of pathogens before each production cycle.
Homogeneous treatment even under full load, thanks to the strategic distribution of steam injectors and the active recirculation of hot air, ensuring uniform disinfection of up to 16 pallets of crates simultaneously, without cold zones or thermal shadows.
Easy integration into daily operations, allowing the thermal cycle to be completed within a maximum of 2 to 3 hours, without interrupting the production rhythm or introducing complex processes for plant personnel.
Hygienic, chemical-free process aligned with food safety, eliminating the need for disinfectants, reducing waste and ensuring a complete “biological reset” of the reusable boxes, compatible with high-value crops and raw consumption.
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:
- 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.
Haven't found the answers to your questions?
Please send us a question or download all the information
USES OF STEAM IN INDUSTRY AND OTHER BUSINESSES
Other similar success stories using steam
The use of steam is gaining popularity in several industries due to its efficiency and environmental benefits..
In our "Success Stories" section, you can discover more about companies that have adopted this technology and have achieved successful results in terms of efficiency and sustainability. Click on the success stories to learn more details.
Original situation: Challenges posed by the client: A biotech company needed to secure a stable, safe and validatable supply of steam to power its fermenters and other critical thermal processes. The existing installation, the result of the plant’s accelerated growth, had several limitations that made it difficult both for daily operation and to meet the […]
Original situation: Challenges posed by the client: An important company in the food industry had a cooler consisting of two spiral towers (a total of 675 meters of conveyor), a key part of its production line. However, the existing cleaning system had serious limitations in terms of efficiency and output quality. The washer integrated into […]