Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit type a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market leader for fresh comfort merchandise due to its quality and expertise. Since early 2019, the vacuum provide 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 contemporary facility in Jagsthausen, a city within the German state of Baden-Württemberg. To enable it to produce contemporary raw produce all yr round, the company has its own growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the whole product vary can be equipped year-round, offered to finish customers across Germany through supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls under the company’s own label, as nicely as for third get together brands. Gartenfrisch Jung’s historical past dates again to 1795. What began out as a small piece of farmland has now reworked into integrated, managed growers of salads and vegetables and one other arm for processing these products. As a family enterprise, Gartenfrisch Jung has been passed from one technology to the following ever since it started. The expertise gained as a result has therefore grown steadily, resulting in the company’s successful improvement and a prime quality commonplace of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked food every single day. This is equivalent to handling 2,000 pallets, that are then delivered to customers by eighty 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 have been outfitted with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These 13 vacuum pumps were used to evacuate the trays to the required vacuum degree prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continuously throughout these shifts, aside from throughout breaks. During a 3rd shift, the manufacturing services are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in cost of expertise at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, as a outcome of the warmth radiated by the 13 vacuum pumps was putting a pressure on the air con system within the manufacturing amenities, that are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the state of affairs and really helpful a centralized vacuum provide, which might be arrange in a non-air-conditioned room outside the manufacturing facilities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum degree of 400 millibars, Busch really helpful utilizing MINK claw vacuum pumps. This kind of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free operating precept, which means that the moving elements contained in the vacuum pump don’t are available contact with one another. In turn, no oil-based lubrication is required and all upkeep work associated to the utilization of oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was equipped with a motor with a nominal motor ranking of 8 kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to make certain that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum provide enabled the entire put in motor ranking to be decreased from 50.2 to sixteen kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. most energy. This would correspond to a 68 % reduction in energy consumption. However, in follow Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a decreased rotational velocity. After several months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the whole vacuum provide. This is especially linked to the truth that the twelve packaging strains do not all all the time run at maximum pace and never all of the machines are in use all the time. The demand-based management system then decreases the rotational pace to reduce back the output, meaning that the system only provides the efficiency that’s truly required. In practice, this equates to power savings of over ninety % for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every ensure that the required vacuum degree is out there in the packaging chambers as soon as it’s wanted within the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved strain from the air con system. This meant that the air conditioning system might be turned right down to maintain the room temperature between 5 and 6 degrees Celsius. The financial savings in energy prices because of lowering the air-con output haven’t been measured. However, it might possibly usually be assumed that the change resulted in a significant discount within the energy consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the person MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are nearly maintenance-free. Kickstart is restricted primarily to the annual preventive change in gear oil. This is carried out by a Busch service technician. With the centralized vacuum system, Jochen Neff has created a extremely energy-efficient, dependable and economical vacuum provide for packaging his convenience merchandise.
Fig: 1: One of twelve strains used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the 2 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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