Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market leader for recent comfort products due to its high quality and experience. Since early 2019, the vacuum provide to its tray sealer packaging machines has been exceptionally energy-efficient following the set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its comfort meals in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to provide contemporary uncooked produce all year spherical, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the whole product range may be provided year-round, sold to finish users throughout Germany via supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, as nicely as for third party brands. Gartenfrisch Jung’s history dates back to 1795. What started out as a small piece of farmland has now transformed into built-in, managed growers of salads and vegetables and one other arm for processing these merchandise. As a household enterprise, Gartenfrisch Jung has been passed from one generation to the next ever because it began. The expertise gained in consequence has subsequently grown steadily, leading to the company’s successful development and a high quality standard of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food every single day. This is equivalent to dealing with 2,000 pallets, that are then delivered to clients by 80 refrigerated vehicles.
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 outfitted with one rotary vane vacuum pump every, although one machine had two vacuum pumps. เกจวัดแรงอัดกระบอกสูบ had been used to evacuate the trays to the required vacuum level prior to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continually throughout these shifts, apart from throughout breaks. During a 3rd shift, the manufacturing services are cleaned while all machinery is stationary.
Jochen Neff, who is in management of expertise at Gartenfrisch Jung, was on the lookout for another vacuum supply, because the heat radiated by the thirteen vacuum pumps was placing a pressure on the air con system in the manufacturing 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 scenario and beneficial a centralized vacuum supply, which might be arrange in a non-air-conditioned room exterior the manufacturing services.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum degree of four hundred millibars, Busch beneficial using MINK claw vacuum pumps. This kind of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which means that the shifting elements inside the vacuum pump don’t are available contact with each other. In turn, no oil-based lubrication is required and all maintenance work associated to the use of oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was geared up with a motor with a nominal motor ranking of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same variety of operating hours.
Centralizing the vacuum provide enabled the entire installed motor ranking to be lowered from 50.2 to 16 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 percent discount in power consumption. However, in practice Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a decreased rotational speed. After several months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the complete vacuum supply. This is principally linked to the truth that the twelve packaging traces do not all always run at maximum velocity and never all the machines are in use on a regular basis. The demand-based control system then decreases the rotational pace to reduce back the output, that means that the system solely offers the efficiency that’s actually required. In practice, this equates to energy savings of over 90 p.c for vacuum generation.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is linked to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every ensure that the required vacuum degree is out there within the packaging chambers as quickly as it is needed in the packaging cycle. Removing the thirteen original vacuum pumps from the production areas relieved pressure from the air con system. This meant that the air-con system could possibly be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The savings in vitality costs as a end result of decreasing the air-con output haven’t been measured. However, it could usually be assumed that the change resulted in a significant reduction within the power consumed by the air-con system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the individual MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is proscribed mainly 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 extremely energy-efficient, reliable and economical vacuum provide for packaging his comfort products.
Fig: 1: One of twelve traces used to bundle comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the two vacuum vessels in the background
Fig. three: Comparison of energy consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020

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