Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market leader for fresh comfort merchandise thanks to its high quality and expertise. Since early 2019, the vacuum supply to its tray sealer packaging machines has been exceptionally energy-efficient following the installation of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its comfort foods in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to produce fresh uncooked produce all yr spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the entire product range can be supplied year-round, bought to end users throughout Germany through grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third get together brands. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now reworked into built-in, controlled growers of salads and greens and another arm for processing these products. As a household business, Gartenfrisch Jung has been passed from one generation to the subsequent ever because it began. The expertise gained in consequence has therefore grown steadily, leading to the company’s profitable development and a prime quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked meals every single day. This is equal to handling 2,000 pallets, that are then delivered to prospects by 80 refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the previous, these packaging machines had been equipped with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps have been used to evacuate the trays to the required vacuum degree previous to sealing. pressure gauge trerice ราคา -shift operation is in place on all twelve packaging lines. The vacuum pumps ran continually all through these shifts, aside from throughout breaks. During a 3rd shift, the manufacturing amenities are cleaned while all machinery is stationary.
Jochen Neff, who is in charge of expertise at Gartenfrisch Jung, was looking for an alternative vacuum supply, because the heat radiated by the thirteen vacuum pumps was placing a strain on the air conditioning system within the production amenities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum provide, which could be arrange in a non-air-conditioned room exterior the production services.
Because Jung’s convenience products have the ideal vacuum for packaging at a vacuum stage of 400 millibars, Busch beneficial using MINK claw vacuum pumps. This type of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free operating precept, which signifies that the transferring elements inside the vacuum pump don’t come in contact with each other. In flip, no oil-based lubrication is required and all upkeep work related to the usage of oil as an operating fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was equipped with a motor with a nominal motor ranking of 8 kilowatts. However, one of the three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the identical number of working hours.
Centralizing the vacuum supply enabled the total put in motor score to be reduced from 50.2 to sixteen kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. most power. This would correspond to a sixty eight p.c reduction in power consumption. However, in practice Jochen Neff has found that solely one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational speed. After a quantity of months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the entire vacuum supply. This is especially linked to the reality that the twelve packaging strains do not all at all times run at most pace and not the entire machines are in use all the time. The demand-based management system then decreases the rotational speed to minimize back the output, which means that the system only offers the performance that’s really required. In practice, this equates to power savings of over ninety p.c for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is linked to the packaging machines by way of a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every make certain that the required vacuum stage is on the market within the packaging chambers as quickly as it is wanted within the packaging cycle. Removing the 13 original vacuum pumps from the manufacturing areas relieved strain from the air-con system. This meant that the air conditioning system could probably be turned down to keep the room temperature between 5 and 6 degrees Celsius. The savings in vitality prices on account of lowering the air-con output haven’t been measured. However, it could possibly generally be assumed that the change resulted in a major reduction within the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep may be carried out on the person MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is restricted primarily to the annual preventive change in gear oil. This is performed by a Busch service technician. With the centralized vacuum system, Jochen Neff has created a highly energy-efficient, reliable and economical vacuum supply for packaging his comfort products.
Fig: 1: One of twelve traces used to package comfort products on tray sealers

Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two vacuum vessels in the background

Fig. three: Comparison of energy consumption for a decentralized and centralized vacuum provide

Image rights: Busch Vacuum Solutions

Busch Vacuum Solutions

Global Marketing – Uli Merkle

10 March 2020

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