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Key Outcomes

  • 12-month Return On Investment (ROI)

  • 93% time saving allowing skilled workers to focus on high value tasks

  • 98.5% water and 100% detergent reduction

  • Improved food safety

  • Turn-around time reduced by 100%

Problem Summary

A chocolate cake and baked goods manufacturer (“the client”) had bottleneck issues with their conveyor system cleaning process. The process was identified as a burden on production, labour and utility costs.

The conveyor system is a KHD flat belt conveyor.

Three factory staff were required to clean the conveyor system at the end of each shift for 45 to 60 minutes. The process used 200 litres of water and detergent, and then left overnight to dry ready for production the following day. After the belt had been cleaned an additional 15 to 20 minutes was required to wash the floor and clean left over conveyor debris.

Bio-Steams' Solution

Bio-Steam reviewed the cleaning process and recommended they use a KHD 9kW steam generator. The client invited Bio-Steam to trial their innovative solution on the process which allowed them to demostrate the benefits to key stakeholders. 

A busy production schedule meant a very short window to trial the solution. This wasn’t as issue for Bio-Steam as their steam vapour technology is designed with plug and play principles to suit manufacturing environments. The steam generator was installed and ready for commissioning within one hour. In the first test cycle the 12 metre conveyer belt ran for three revolutions before being inspected by Management, Quality Assurance and the Sanitisation Team.

The trial yielded great results that exceeded stakeholder expectations. The belt was completely clean, dry and ready for the next production run. The Bio-Steam solution did this using only three litres of water, zero chemicals and all waste was contained in a vacuum system.

Results

  • Customer satisfaction; the customer immediately ordered the Bio-Steam solution and has subsequently purchased numerous other steam vapour cleaning solutions from Bio-Steam.

  • Value for money; the Bio-Steam solution provided an estimated ROI of 12 months.

  • Labour savings; immediate labour savings achieved. Cleaning staff for the conveyor system reduced from three staff for up to 60 minutes to one staff member for 10 minutes (including set up and breakdown of the equipment). This represents a labour saving of 93%.

  • Water savings; water consumption per clean reduced from 200 litres to 3 litres representing a 98.5 % reduction.

  • Asset productivity; The Bio-Steam solution ensures the asset is fully sanitised and ready for the next production cycle immediately, the old process required overnight drying.

Discuss how you can save money and time on commercial cleaning needs with Bio-Steam.
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Related Projects

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Key Outcomes 

  • Much higher accuracy and repeatability achieved with non-intrusive clamp-on technology compared to the previously installed open channel meter
  • 3 to 4 times more cost effective than in line flow meter options
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  • Better measurement performance than the other clamp-on flow meters tested by the customer
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  • Great local service and support through Flowservices (FLEXIM distributor)

Business Problem 

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Key Outcomes 

  • 75% reduction in cleaning labour
  • No plant shut down required

Business Productivity Problem

A specialist bread processor installed a $1m plant upgrade and was experiencing difficulties cleaning key equipment and components of the process. This necessitated complete shut-down of production and four factory workers tasked with clean the equipment over a 12-hour shift. This was happening every 7-10 days.

The Solution
After visiting the site and collaborating with Production and Maintenance teams, it was agreed that a trial of a 9 kW steam and vacuum unit would be beneficial.

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Innovative Cleaning System Improves Food Safety

Key Outcomes 

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Problem Summary
A specialist fresh vegetable food processor with unique conveyor belt system design was experiencing food safety challenges particularly around Listeria and Salmonella. This presented the challenge of having to remove and wash belts at the end of every production day.

Solution
A site review and small scale trial was carried out to prove the concept and collect data. Following this trial, the customer ordered a KHD Return Mounted Belt cleaner.
This was installed along with an industrial vacuum system. The belts are continuously steam cleaned on every rotation and vacuum dried as they leave the cleaning head. The system uses as little as 30 litres of water per hour.
 

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costs on cleaning processes?

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