Industrial vapour extraction in the food sector

Case study: Occupational safety and vapor management in industrial sanitation processes

In food production environments, high-vapor sanitization processes pose a challenge that goes far beyond simple thermal comfort. When vapors are left unmanaged, they accumulate in the environment, reducing visibility, increasing structural humidity, and creating real risks for workers. This is precisely the situation Meridiana Aspiratori faced at Calispa SpA , a food company in Castel San Giorgio (SA), where they installed four TOR90 series extraction towers to solve a problem that, until then, had no solution.

When steam becomes a safety issue

Industrial sanitization equipment in the food industry uses high-temperature steam. During operation, they release large quantities of saturated steam into the environment, which, without an adequate extraction system, quickly builds up in the production space.

The consequences aren’t just thermal discomfort. Dense steam significantly reduces visibility, just as happens in dense fog: workers struggle to orient themselves, see obstacles, or see nearby colleagues. In an industrial environment where people, forklifts, and machinery move around, this condition poses a real risk to workplace safety. Added to this are the problems posed by excess humidity: condensation on surfaces, deterioration of structures, mold growth, and difficulty meeting the hygiene and regulatory requirements of the food industry.

Calispa found itself in this situation. It had no pre-existing plant solutions and no vapor capture or extraction system. A technical vacuum that required a structured intervention, not a makeshift response.

Saturated steam as a technical challenge is not enough to extract it, it must be managed

The first response that comes to mind when faced with a steam-saturated environment is to install extractors. But in the case of Calispa , the technical challenge was more complex than it might seem.

The fluid being handled isn’t hot air. It’s saturated steam, extremely charged with moisture and heat. When this type of fluid passes through a conventional extraction tower, a critical condition is created inside the electric motor. The temperature difference between the passing steam and the inside of the motor casing generates condensation on the windings. The water that forms in this way (invisible and silent) is one of the main causes of premature failure of electric motors in humid environments. It deteriorates the insulation, triggers short circuits, and reduces the component’s useful life.

This criticality emerged during the inspection carried out by Meridiana Aspiratori . The solution wasn’t simply sizing the air flow rate, but choosing the right configuration for a fluid with such specific characteristics.

Site inspection, sizing and technical choice

The project followed a three-phase process: initial consultation, on-site inspection, and technical sizing of the system.

During the inspection, the team analyzed the characteristics of the sanitization machinery, the space volumes, the distribution of steam sources, and the operating conditions. This analysis led to the technical proposal: four TOR90 series 2.2 kW class H extraction towers , positioned on the ceiling to ensure uniform destratification of the vapors produced.

The distinctive technical choice of this project concerned the configuration of the electric motors. Based on Meridiana Aspiratori ‘s recommendations , the towers were equipped with:

• Motors in insulation class H , suitable for high operating temperatures and conditions of sustained humidity.
• Anti-condensation heaters , heating resistors that keep the inside of the motor at a temperature slightly higher than ambient temperature during periods of inactivity, preventing the formation of condensation on the windings.

This configuration was neither requested by the customer nor part of an initial specification, but emerged from the technical analysis of the fluid to be managed. It is a concrete example of how consulting goes beyond product supply, but also integrates an engineering assessment of the application context, with the goal of ensuring long-term reliability and not just commissioning performance.

Extracted vapors, safe environments

The results after installing the four extraction towers were immediately visible. The vapors produced by the sanitization machinery are now captured and vented outdoors; they do not accumulate in the environment, do not condense on surfaces, and do not create the domino effect of heat and humidity that characterized the previous system.

From a safety perspective, the improvement is substantial. Visibility in the production area has returned to normal, eliminating the risk associated with opaque environments. Thermal and humidity conditions are stable, benefiting both operator comfort and the integrity of the structures and equipment.

The choice of class H electric motors with anti-condensation heaters ensures that the system maintains this effectiveness over time, even under the most demanding operating conditions, protecting the investment and reducing the risk of extraordinary maintenance due to electrical component failure.

Intervening in a context like Calispa’s means addressing industrial steam for what it truly is: a fluid with specific characteristics that requires a targeted technical response. Installing the right product isn’t enough if it hasn’t been configured for the context in which it will operate. This is where the value of consulting comes into its own.