Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for contemporary convenience products thanks to its 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 foods in a modern facility in Jagsthausen, a city in the German state of Baden-Württemberg. To permit it to produce fresh uncooked produce all 12 months round, the company has its own growers in Germany and Portugal. Cultivation in two different climate zones ensures that the complete product vary can be provided year-round, bought to end users across Germany through supermarket chains and low cost stores. 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 history dates back to 1795. What started out as a small piece of farmland has now reworked into integrated, controlled growers of salads and vegetables and another arm for processing these products. As a family business, Gartenfrisch Jung has been handed from one generation to the subsequent ever since it began. The expertise gained as a result has subsequently grown steadily, leading to the company’s profitable improvement and a top quality standard of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw meals daily. เกจวัดแรงดันราคา is equivalent to handling 2,000 pallets, which are then delivered to customers by 80 refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the past, these packaging machines have 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 stage previous to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continually throughout these shifts, aside from throughout breaks. During a third shift, the manufacturing amenities are cleaned whereas all machinery is stationary.
Jochen Neff, who’s in management of know-how at Gartenfrisch Jung, was in search of an alternative vacuum supply, because the warmth radiated by the 13 vacuum pumps was placing a pressure on the air conditioning system in the manufacturing facilities, which are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the scenario and recommended a centralized vacuum provide, which could be arrange in a non-air-conditioned room outside the production facilities.
Because Jung’s convenience products have the ideal 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 operating precept, which means that the moving parts inside the vacuum pump do not are available contact with one another. In turn, no oil-based lubrication is required and all maintenance work associated to the use of oil as an operating fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was geared up with a motor with a nominal motor ranking of eight kilowatts. However, one of many three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum supply enabled the whole installed motor score to be decreased from 50.2 to 16 kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. maximum power. This would correspond to a sixty eight % reduction in power consumption. However, in apply Jochen Neff has found that solely one of many two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational velocity. After a number of months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the whole vacuum provide. This is mainly linked to the reality that the twelve packaging traces don’t all all the time run at maximum speed and not the entire machines are in use all the time. The demand-based management system then decreases the rotational pace to reduce back the output, which means that the system solely offers the efficiency that’s really required. In follow, this equates to energy financial savings of over 90 % for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make certain that the required vacuum level is available in the packaging chambers as soon as it’s wanted within the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air con system could possibly be turned right down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in vitality costs because of lowering the air conditioning output have not been measured. However, it could usually be assumed that the change resulted in a big discount in the power consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is proscribed mainly 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 highly energy-efficient, dependable and economical vacuum provide for packaging his comfort merchandise.
Fig: 1: One of twelve lines used to bundle convenience products on tray sealers

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

Fig. 3: 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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