Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market chief for fresh convenience products due 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 set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its comfort meals in a modern facility in Jagsthausen, a city in the German state of Baden-Württemberg. To permit it to produce recent raw produce all yr round, the company has its personal growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the complete product vary can be provided year-round, offered 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 properly as for third party brands. Gartenfrisch Jung’s historical past dates again to 1795. What began out as a small piece of farmland has now reworked into integrated, controlled growers of salads and greens and one other arm for processing these merchandise. As a family enterprise, Gartenfrisch Jung has been handed from one technology to the following ever because it began. The experience gained as a result has therefore grown steadily, resulting in the company’s profitable development and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw meals every day. This is equal to dealing with 2,000 pallets, that are then delivered to customers by 80 refrigerated autos.
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 were equipped with one rotary vane vacuum pump every, though one machine had two vacuum pumps. These 13 vacuum pumps had been used to evacuate the trays to the required vacuum degree previous to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly all through these shifts, apart from throughout breaks. During a third shift, the manufacturing facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in control of expertise at Gartenfrisch Jung, was looking for an alternative vacuum provide, because the heat radiated by the thirteen vacuum pumps was putting a pressure on the air-con system within the production facilities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the scenario and recommended a centralized vacuum provide, which might be set up in a non-air-conditioned room outdoors the manufacturing services.
Because Jung’s comfort products have the ideal vacuum for packaging at a vacuum level of four hundred millibars, Busch really helpful using MINK claw vacuum pumps. This kind of vacuum pump has the best efficiency factor out of all mechanical vacuum pumps. This is a result of their contact-free operating precept, which implies that the shifting parts contained in the vacuum pump do not are obtainable in contact with each other. In turn, no oil-based lubrication is required and all upkeep work related to using 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 equipped with a motor with a nominal motor ranking of eight kilowatts. However, one of the three vacuum pumps is exclusively 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 provide enabled the entire put in motor rating 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. maximum energy. This would correspond to a sixty eight % discount in energy 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 speed. After a number of months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the complete vacuum supply. This is principally linked to the reality that the twelve packaging traces don’t all all the time run at maximum pace and not all of the machines are in use all the time. The demand-based control system then decreases the rotational velocity to scale back the output, which means that the system only provides the efficiency that is truly required. In practice, this equates to power financial savings of over ninety % for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every since. เกจวัดแรงลม is linked to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make sure that the required vacuum degree is on the market in the packaging chambers as quickly as it’s wanted in the packaging cycle. Removing the 13 authentic vacuum pumps from the production areas relieved strain from the air-con system. This meant that the air-con system might be turned right down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in power prices on account of reducing the air con output have not been measured. However, it can usually 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 can be carried out on the person MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is proscribed 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 products.
Fig: 1: One of twelve strains used to package comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the two vacuum vessels in the background
Fig. three: Comparison of vitality 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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