Frequently Asked Questions About Steam Generators - CERTUSS FAQ

A steam generator heats water until it turns into steam. The feedwater is supplied to the steam generator and heated by the energy supplied. As soon as the required temperature is reached, steam is produced, which can then be used for various industrial processes.

A steam generator thus converts water into usable steam with the help of energy. Depending on the model, the energy can come from sources such as gas, oil, or electricity.

A rapid steam generator is a steam generator that is ready for operation and produces steam within a short period of time. Unlike a conventional large boiler, it does not maintain a large volume of water at a constant temperature.

Rapid steam generators operate with a small volume of water and can therefore respond quickly to changes in steam demand. They are particularly well-suited for industrial applications where steam is needed flexibly and on demand.

A rapid steam generator produces steam particularly quickly because the water is heated and vaporized directly during operation. At CERTUSS, this is achieved using flow-through technology: The water flows through a system of pipes, is heated in the process, and exits the steam generator as steam.

This eliminates the need to heat a large volume of water first. Depending on the model, CERTUSS steam generators reach their full steam output in as little as 3–5 minutes.

This makes rapid-start steam generators particularly appealing for businesses with fluctuating steam demands or frequent start-up and shutdown cycles.

Pure steam is steam that must meet particularly high purity standards. It is used in applications where the steam itself must not introduce any undesirable substances into the process.

Typical areas of application include the pharmaceutical industry, medical technology, and certain sterilization processes. For such applications, CERTUSS offers configurations for pure steam in accordance with EN 285 upon request.

Saturated steam is steam that is in equilibrium with water at a specific pressure and the corresponding saturation temperature. When heat is added, more water can evaporate; when heat is removed, steam can condense back into water.

Saturated steam is used particularly frequently in industry for heating, cooking, sterilizing, and cleaning. CERTUSS steam generators produce saturated steam at various pressure levels as standard.

An economizer recovers the heat that would otherwise be lost in the exhaust gases of a gas- or oil-fired steam generator. This heat is used to preheat the feedwater before steam is actually generated.

As a result, less additional energy is required, and fuel consumption can be reduced. An economizer can thus help increase the efficiency of a steam system and lower operating costs.

Industrial steam is primarily used for heating, cooking, sterilizing, drying, and cleaning. In these applications, steam acts as a heat transfer medium and can transfer its energy to other processes with exceptional efficiency.

Typical applications include..

• Food and beverage industry: Cooking, heating, and cleaning
• Breweries: Brewing processes and cleaning
• Pharmaceutical industry: Sterilization and process heat
• Chemical industry: Heating and various production processes
• Textile industry: Washing, dyeing, and finishing
• Hospitals: Sterilization and process steam supply

The amount and quality of steam required depend on the specific process and individual steam needs.

In a water-tube boiler, the water to be heated is contained within tubes. The heat source heats the tubes from the outside, causing the water inside to heat up and be partially or completely converted into steam.

The basic principle is therefore: Water flows through tubes, is heated by the heat source, and steam is produced.

CERTUSS steam generators also operate using a pressurized coil system, which sets them apart from traditional large-capacity water boilers. Thanks to their low water volume and flow-through technology, they can generate steam quickly and respond flexibly to actual demand.

A steam generator produces steam from water, and various technical designs can be used for this purpose. A traditional steam boiler often has a larger water capacity, while rapid steam generators, such as the CERTUSS systems, operate with a comparatively small amount of water and use flow-through technology.

As a result, the systems differ in terms of startup time, water capacity, size, and response to fluctuating steam demand, among other factors.

CERTUSS steam generators produce saturated steam as standard at various pressure levels—up to 32 bar design pressure, depending on the model. Saturated steam is in thermal equilibrium with the condensate and is used in numerous industrial processes for heating, cooking, sterilizing, and cleaning.

For special applications, configurations for superheated steam or pure steam in accordance with EN 285 are also available upon request. Superheated steam is above the saturation temperature and is used when condensation must be kept to a minimum.

Pure steam, on the other hand, meets specific purity requirements and is used, for example, in medical and pharmaceutical technology.
CERTUSS thus offers solutions for a variety of requirements regarding steam quality, temperature, and purity.

CERTUSS steam generators can be used in many different industries - anywhere where reliable steam is required. Our customers include companies from the

• Food and Beverage Industry
• Pharmaceutical and Chemical Industries
• Laboratory and Medical Technology

CERTUSS is also active in the following sectors…

• Hospitals
• Hospitality
• Entertainment
• Aviation
• Automotive Industry
• Textile Industry  

…where steam is used for heating, sterilization, cooking, and cleaning, among other things. As a result, CERTUSS steam generators cover a wide range of industrial and commercial applications.

Thanks to the continuous-flow technology, full steam output is reached within approximately 3–5 minutes after startup. This eliminates the need for a time-consuming and costly preheating phase, as is the case with conventional boilers.

The ability to reach operating readiness quickly is a significant advantage of CERTUSS steam generators, particularly in applications involving frequent start-up and shutdown cycles.

Our systems comply with the European Pressure Equipment Directive (PED 2014/68/EU) and bear the CE marking in accordance with this directive. Country-specific certifications, such as ASME, are also part of our portfolio. Since a pressurized coil system is used instead of a traditional pressure vessel, regular pressure vessel inspections may not be required, depending on the water capacity and country-specific regulations.

Safety devices include, among others:

• Safety valve
• low-water protection
• pressure and temperature limiters
• flame monitoring

The specific requirements that apply in each case depend on the country of installation and the specific system configuration.

 

CERTUSS steam generators achieve efficiency levels (fossil fuel) of up to 94 percent; the electric model reaches up to 99 percent. Thanks to the modular control system and rapid response to load changes, energy is used only when actually needed. The energy efficiency of a CERTUSS steam generator also depends on the specific operating conditions, load profile, and system design.

Our systems can be optionally equipped with an interface. This enables remote monitoring solutions as well as integration into higher-level control systems (SCADA/BMS). Possible options include:

• Modbus TCP
• Modbus RTU
• Profibus
• Profinet IO

This allows CERTUSS steam generators to be integrated into existing automation and building management systems.

On our website, under the “Sales Contacts” section, you can quickly and easily find your regional contact or sales partner. Alternatively, you can reach us directly at any time at verkauf(at)certuss.com. This allows you to contact the representative responsible for your region directly for consultation, design, and a quote.

For a precise design, we need:

• Desired steam flow rate (kg/h)
• Operating pressure (bar)
• Energy source (gas, oil, electricity)
• Information about the installation site and water quality

We would be happy to send you our design questionnaire. This information forms the basis for the technical design of a suitable CERTUSS steam generator.

Standard models, including accessories, are generally available within 6–8 weeks after the drawings are approved. For custom configurations or larger systems, please contact your CERTUSS representative directly. The specific delivery time depends primarily on the model, version, and scope of the desired configuration.

In addition to traditional purchases, CERTUSS also offers rental solutions for select steam generators. Which option is right for your company depends, among other things, on:

• the application
• the power requirements
• the planned duration of use

We also work closely with a service provider in the areas of rent-to-own and leasing.

Our experts will be happy to advise you and work with you to develop the right solution. In addition to the traditional purchase option, alternative models for the procurement and financing of select CERTUSS steam generators are also available.

Yes. Our solutions are used worldwide: With more than 16,000 systems installed in over 130 countries, we have extensive experience across a wide range of industries and applications. Under the “Industries” menu item on our website, you’ll find numerous case studies and reference projects from various industries - including the Füchschen Brewery in Düsseldorf and Meyer Menü in Bielefeld. These real-world examples demonstrate how our solutions are being successfully implemented in different regions and industries. Interested parties can explore specific application examples there, organized by industry and area of application.

CERTUSS maintains a comprehensive inventory of replacement parts and guarantees the availability of wear parts and replacement parts for over 20 years. Critical parts can also be stored at the customer’s site as stock kits. This supports the long-term maintainability of the systems and ensures availability during ongoing operations.

Yes. CERTUSS offers operator training for steam generators directly at the customer’s site. Well-trained personnel reduce downtime and contribute to the safe and efficient operation of the system. The training courses provide practical knowledge for the operation and maintenance of CERTUSS steam generators.

Thanks to our comprehensive service network throughout Germany, CERTUSS can respond quickly in the event of a malfunction. For particularly critical applications, we offer service contracts with defined and prioritized response times. This ensures that a suitable service concept is available for a variety of requirements.

Yes. We offer customized service contracts with defined response times and regular inspections. This allows you to plan your budget with confidence and avoid unplanned downtime. Please contact CERTUSS Service for a customized quote. The service contracts can be tailored to the specific requirements of your system and operations.

An annual inspection and maintenance check is recommended to ensure long-term operational safety and efficiency. Depending on operating hours and water quality, shorter intervals may be advisable. The appropriate maintenance interval should therefore be based on the actual operating conditions of the specific system.

That depends heavily on local energy prices and the load profile. We would be happy to prepare a customized cost-benefit analysis for your location and operations. A general comparison of the steam price per metric ton is therefore not reliable without information on the energy source, energy price, and operational profile.

Yes. As of August 2026, you may be eligible to apply for grants for electrically powered systems in the EMX series, depending on the state and intended use—for example, through the BAFA or state-specific programs. Our sales team will be happy to advise you on currently available programs. Which grants you can actually apply for depends on the specific grant program, location, and project.

The total costs consist of:

• Investment
• Energy costs
• Maintenance and operation

Thanks to high efficiency, low maintenance requirements, and a long service life, the TCO of CERTUSS systems is generally significantly lower than that of comparable large-capacity water boilers. For a reliable assessment, TCO should always be evaluated based on the specific location and operating profile.

CERTUSS systems are particularly cost-effective in the following situations:

• modular steam demand
• limited space
• frequent start-up and shutdown cycles
• when complex boiler operator monitoring is not desired

Thanks to low downtime losses, the investment pays for itself quickly. Whether a CERTUSS steam generator is more cost-effective than a large boiler depends on the specific steam demand, load profile, and system design.

Yes. We support our customers with technical documentation, consumption analyses, and certificates that facilitate ESG-compliant reporting. The specific documents required in each case depend on the company’s reporting obligations and requirements.

When switching from gas-fired to electric CERTUSS systems powered by green electricity, direct CO₂ emissions can be reduced to zero. The exact reduction depends on the previous energy mix and consumption. Therefore, previous energy consumption and the energy sources used are key factors for a specific calculation.

Our sales team will guide you from the initial analysis through to commissioning. Together, we will evaluate:

• technical feasibility
• economic viability
• potential grant applications

In doing so, we may consider the following aspects, among others:

• existing steam demand
• electrical connection capacity
• installation conditions
• the existing system design

Yes. The EMX series is fully electric and produces CO₂-free steam—provided that green electricity is used. It is ideal for companies looking to reduce their Scope 1 emissions. Electric steam generation thus offers a way to reduce direct CO₂ emissions during steam production.

Since 1957, CERTUSS has been synonymous with steam generators without pressure vessels. This technology makes our systems safer, more compact, and quicker to bring online than conventional steam boilers—featuring technology that has been proven safe over many years, dating back to 1957. This proven technology forms the basis for the compact design and rapid steam delivery of CERTUSS systems.

CERTUSS has an international sales and service network with partners and representatives in more than 50 countries worldwide. In addition, many of our sales partners serve multiple countries and regions. CERTUSS is headquartered in Krefeld, Germany. As part of the Miura Group, CERTUSS has an extensive global sales and service network.

Since CERTUSS was founded, steam generators have been installed in more than 130 countries worldwide. Today, over 16,000 CERTUSS steam generators are in operation around the globe. This international installation base, spanning several decades, underscores the reliability, durability, and worldwide acceptance of CERTUSS steam technology across a wide range of industries. As a result, CERTUSS has a long-standing international installed base across numerous industries and application areas.