Month: May 2024

Clean Steam System Design Fundamentals

Clean steam is saturated steam made from purified water that is used to sanitize equipment in cleanrooms, pharmaceutical manufacturing and processing facilities, and medical settings. It allows for non-contact cleaning of equipment, including corners and tight or enclosed spaces.

In addition to generating clean steam, the system must be designed to prevent internal corrosion both within the steam system and in the equipment being sanitized. Microbes and other contaminants also need to be prevented from entering the steam system and reaching equipment or products. Controlling contaminants prevents products from becoming tainted and increases the service life of equipment.

Here, we’ll look at how preventing contamination in a clean steam generation system keeps equipment sterile and maintains product quality and purity.

How a Clean Steam Generator Works to Prevent Corrosion

Avoiding corrosion is essential to the upkeep and operation of clean steam generation and processing equipment. Keeping particles of rust and other corrosion by-products out of equipment and manufactured products is critical to product quality and safety as well.

Standard utility steam used for industrial processes that don’t require sterile steam is generated with water heated in a boiler. The components in the system can be made with various metals, most of which can rust. As a result, the water is generally treated with anti-corrosion chemicals to prevent rust and other forms of corrosion in the steam generator system and in the equipment it feeds.

Unlike the water used for utility steam, there are no corrosion inhibitors in clean steam feedwater. In most cases, potable purified water or water filtered by reverse osmosis (RO) is used to create clean steam. For this reason, it is important to use materials that resist corrosion such as 316L stainless steel, titanium, and PTFE or EPDM polymer materials.

Even when 316L stainless steel is used, rouging corrosion can occur, in which the steel’s surface becomes covered with a red-brown film. While not problematic itself, this film can develop a powdery coating, which can detach and contaminate the steam. Periodic derouging removes the build-up.

Preventing Entry of Contaminants

Clean steam must always be free of contaminants at the point of use. These can include chemicals, rust or other particles from the corrosion process, bacteria, molds, and dirt or debris. Care must be taken to avoid common causes of contamination, including:

• Leaks in steam traps, hoses, or feedwater tanks
• Outside air that gets pulled into the system
• Standing condensation that permits bacterial growth
• Corrosion in tanks, heat exchangers, or other equipment
• Bacteria that grow through RO membranes and other surfaces can get into the system over time

Preventing Microbial Growth

Steam can kill bacteria and spores at typical operating pressures, and therefore components of a clean steam generation system that experience continuous exposure to steam will remain free from these contaminants. However, if condensate collects in the system and cools, the standing water can create an environment that permits bacterial growth.

Byproducts from the destruction and breakdown of bacteria, including endotoxins, remain in the system and cannot be destroyed by the steam. Endotoxins are often lipopolysaccharides from the cell walls of Gram-negative bacteria or pyrogens. They are a major concern in the manufacture and processing of injectable pharmaceutical products.

Standing condensation can be prevented by angling pipes and traps to collect any water that collects. Traps, piping, and tubing should also be checked for leaks or damage regularly.

Contact Electro-Steam for Clean Steam Generators

At Electro-Steam, we provide high-quality, electric-fired clean steam systems for pharmaceutical, medical, and cleanroom use. Our offerings include steam generators and steam sanitization systems and accessories for industrial process steam and food processing applications. Our experienced and knowledgeable team can also design a customized system to meet your requirements.

Contact us to learn more about how clean steam generators work or to request a quote for your application.

Tips to Minimize Contamination With Steam Sterilization

Providing clean steam for pharmaceutical manufacturing and healthcare applications is crucial for ensuring the proper sterilization and safety of products, equipment, medical tools, and patients. Heated and pressurized clean medical steam and pharma steam effectively kill microbial contaminants and help facilities adhere to strict cleanliness criteria to comply with industry quality and safety standards. In this blog, we’ll detail helpful tips for reducing contamination in the pharmaceutical and medical sectors through steam sterilization.

Use Clean Steam

Having contaminant-free steam is important for numerous operations ranging from sanitation to humidification. Pure steam will comply with industry requirements for such processes, which dictate steam’s acceptable dryness, total organic carbon and endotoxin content, and water conductivity.

Lacking any additives or additional substances, clean steam is the result of heating one of the following water sources above 212º F until it vaporizes:

• Water for injection (WFI)
• Highly purified water (DI)
• Purified water (RO)

This process eliminates the risk of source water entrainment and, as long as you maintain these thermal conditions for the appropriate time period, it’s highly effective in eliminating bacteria and microorganisms. When holding temperatures constant, sterilization times will vary based on the type of sterilizer you’re using, an item’s material construction, whether it’s wrapped or not, and other related factors.

Use Proper Clean Steam Systems

Products for markets like healthcare and pharmaceuticals are held to high standards when it comes to safety and quality. They require high-purity processing to minimize the risk of corrosion or product contamination and comply with all industry-based regulations.

Clean steam systems help prevent bacterial growth, consisting of high-grade, non-porous stainless steel parts and assemblies for the material’s hygienic properties. A quality, reputable steam sterilization system should come with the following documentation:

• 3:1 Material certificates
• Certificate of origin
• Certificates of compliance
• Standard test reports
• Surface finish reports

The general principle behind steam sterilization is to ensure that each component or device you’re sterilizing comes into direct contact with the clean steam. Within the controlled environment of an autoclave, you can achieve the proper pressure and temperature conditions for that steam and sterilize items for the necessary time period.

Steam sterilizers are available in two basic varieties: high-speed pre-vacuum sterilizers and gravity displacement autoclaves. Utilizing a vacuum pump to pull air from the sterilizing chamber before steam enters, high-speed pre-vacuum sterilizers provide virtually immediate steam penetration for porous goods. Gravity displacement autoclaves sterilize nonporous items, water, regulated healthcare waste, lab media, and pharmaceutical goods with direct-contact steam. To successfully sterilize wrapped medical supplies, you must maintain temperatures of 270º F in high-speed pre-vacuum sterilizers for 4 minutes and 250º F in gravity displacement autoclaves for 30 minutes.

Comply With Current Good Manufacturing Practices (CGMPs)

The Food and Drug Administration (FDA) establishes and enforces what are called the Current Good Manufacturing Practice regulations. These guidelines set the acceptable standards for:

• Procuring high-quality materials
• Utilizing properly designed systems
• Instituting robust operational procedures
• Developing quality management systems
• Monitoring equipment and its performance
• Identifying and evaluating any deviations in product quality or consistency
• Maintaining the state of your manufacturing and laboratory facilities for quality products and dependable testing results

By having these standardized CGMP regulations in place and adhering to them, your medical or pharma operation can better assure and manage product purity, overall quality, strength, and proper ingredients. CGMPs will help you avoid not only contamination but also manufacturing deviations or mix-ups that would negatively impact your pharmaceuticals and ability to produce a consistent product.

Proactively and Regularly Assess Steam System Performance

The following factors affect the purity levels of steam, which then impacts the quality, safety, and efficacy of finished goods:

• Sterilization system design
• Materials for construction
• Quality of feedwater
• Production practices
• Maintenance procedures

Like with any equipment, it’s important to be proactive about steam system inspections, maintenance, and repairs to ensure continued and optimal performance. Reviewing your equipment periodically lessens the chance that you’ll be caught by surprise and experience downtime in your steam system operation. This also helps guarantee that your system will continue to generate compliant, contaminant-free pure steam suitable for medical and pharmaceutical applications.

Contact Electro-Steam for Clean Steam Sterilization Solutions

Established in 1952, Electro-Steam Generator Corp. is a leading OEM manufacturer of electric steam generators. In fact, we make the most reliable miniature electric steam generator available on the market today. As part of our extensive American-made offerings, our team produces high-quality stainless steel generators in various configurations and sizes to reliably supply medical and pharmaceutical sterilizer equipment like autoclaves with clean steam.

We also offer exceptional service and technical support. Electro-Steam’s expert team is able to diagnose 95% of equipment issues over the phone as you stand in front of it in your facility, even if you lack a mechanical background. A five-year warranty comes standard on our units, with one-year coverage on components. We handle all parts and warranty inquiries quickly and accurately — often with same-day shipments.

Contact us today to learn more about the steam sterilization process and how a steam generator from Electro-Steam can support quality and efficiency in your operations.

Steam vs. Ozone Cleaning for Winemaking

Steam and ozone are common winery sanitization methods that winemakers use to keep cellars and equipment clean. Learn what to look for in an effective sanitation system, the unique features of steam vs. ozone cleaning, and why one might be better than the other.

What to Look for in Winery Sanitation

Wineries and their cellars are often vulnerable to harmful bacteria that can spoil or otherwise negatively affect wine products, which is why these facilities require proper sanitation. Effective sanitation is continuous and covers all processes and equipment, preventing spoilage organisms from spreading throughout the facility and contaminating future wine batches.

The right cleaning method will account for these organisms’ location of origin and travel paths, such as the barrel and the bottling line. Generally, the following elements are what you should seek in a winemaking sanitization system:

• The ability to effectively eliminate many types of spoilage organisms and microbes
• Ease of use to thoroughly sanitize various environments, systems, and processes
• Eco-friendliness
• Safe operation
• Energy efficiency
• Zero negative impact on products, workers, and facilities

Using Ozone in Winemaking

The main benefit and potential disadvantage of ozone is its lack of persistence since it is both unstable and reactive. Unlike other cleaning elements, any ozone not immediately consumed by organic oxidation will simply turn to oxygen. As a result, ozonated water doesn’t need a specialized disposal method, won’t contaminate ponds, and won’t kill beneficial organisms in biomass or septic systems.

While ozone barrel cleaning can be an effective sanitation process, ozone comes with certain disadvantages that may make it unsuitable for winemaking facilities. One downside of using ozone for winery cleaning is its potential safety hazard. Workers who come into contact with isolated ozone may experience symptoms such as headaches, nausea, and respiratory problems. Another disadvantage of using ozone for wineries is its brief half-life, as ozone quickly outgases from its water solution while in the wine barrel.

Why Steam Is Superior for Winemaking

If you want a reliable and safe method for cleaning barrels and other winery equipment, steam is one of the best solutions available. Steam efficiently eliminates the majority of harmful microorganisms by using high temperatures.

Specifically, winery steam cleaner systems use temperatures exceeding 212 °F (100 °C) for five to 10 minutes to deactivate all yeast, bacteria, and fungi in tanks, barrels, and bottling lines. Using dry steam, you can also get rid of spoilage microorganisms highly resistant to SO2, low pH, and high alcohol.

Steam sterilization reaches even the tightest spaces in wine barrels and lines, including narrow openings such as nozzles that would be difficult to reach with ozone cleaning and other methods. Dry steam is particularly beneficial for wood barrels because of its ability to penetrate up to ½” into the wood’s porous surface and kill hidden microorganisms.

Another benefit of dry steam is that it only requires half a gallon of water to clean each barrel, which translates to reduced filling times and reduced expenses. Ultimately, the dry steam cleaning technique offers the most efficient and dependable way to sanitize winemaking equipment, with the added ability to rehydrate wood barrels for wineries, distilleries, and breweries.

Contact Electro-Steam for Steam Generators

If you’re looking for a high-quality winery steam cleaner for your winery, distillery, or brewery, we’ll provide you with the right solution to meet your unique needs. Since 1952, Electro-Steam has grown into a leading provider of safe and reliable industrial steam generators and food safety sanitation systems.

Want to learn more about how barrel steam sterilizers can benefit your winemaking facility or processes? You can contact us today to speak with one of our experts and find the ideal cleaner for your application.

How Does Steam Destroy Microorganisms?

Steam cleaning is an ideal method for sterilizing surfaces. Sterilization involves increasing the temperature of the water until it becomes a gas (vapor), which raises the temperature of a given surface. The high temperatures quickly kill any microorganisms living on the surface.

Various facilities rely on steam generation for sterilization, including hospitals and various other critical care facilities.. Electro-Steam offers a line of steam generators for sterilization in food production, food processing, and even winemaking and bottling. We have been a trusted manufacturer of steam generation equipment since 1952.

How Steam Eliminates Microorganisms

Steam sterilization uses thermal energy from steam to kill microorganisms. During the sterilization process, high-pressure saturated steam comes in contact with lower-temperature surfaces and releases heat from condensation. Microorganisms in a steam sterilizer are killed by exposure, leaving surfaces sterile for production.

Steam sterilization works well for several reasons. Moist air is exponentially more effective at conveying heat energy than dry, hot air. For instance, cooking potatoes in a steam pressure cooker reduces cooking time from several hours to several minutes.

Steam also softens the outer layers that protect microorganisms, coagulating the sensitive inner portions of the microbe in a process similar to cooking an egg white. However, greasy or oily environments can protect microorganisms from the effects of steam. Thoroughly cleaning the treatment area in advance is critical for proper sterilization.

The following variables can be adjusted to ensure the lethality and overall effectiveness of steam:

• The degree of heat exposure
• The duration of exposure
• The volume of moisture

Assess the packaging material and surfaces that you intend to treat. Certain items will not maintain their integrity when exposed to steam. Additionally, moisture can damage sensitive products such as electronics and soft plastics.

How Is Steam Sterilization Performed?

Autoclaves (pressurized vessels) are the most popular moist heat sterilization devices. Autoclaves use pure moist heat to generate clean steam by removing air from the chamber and replacing it with pure, saturated steam.

The full steam sterilization process occurs in three basic steps:

• Preconditioning the chamber and load. Air is removed from the chamber and replaced by saturated steam.
• Running the sterilization cycle. Chamber pressure increases, raising the water’s boiling point to 121 C. Steam heats the chamber walls as it accumulates, raising the temperature of the solution and destroying microbial proteins.
• Removing steam from the chamber. Once steam has been removed, pressure is normalized.

Applications of Steam Sterilization

Moist heat steam sterilization (such as autoclaving) is preferred for sterilizing utensils, instruments, wrapped goods, and hollow items in medical settings. Other applications that depend on moist heat steam sterilization include:

• Food Production
• Winemaking and Bottling
• Food Packaging

Contact Electro-Steam Generators for Steam Generators

Electro-Steam is an OEM manufacturer of steam-generating equipment for a range of applications. Our quality, efficiency, and warranty make Electro-Steam products suitable for pharmaceutical applications, medical settings, food processing and packaging, and more.

Contact us or request a quote to speak with a team member about your steam generation needs today.