Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market chief for fresh comfort merchandise thanks to its 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 in the German state of Baden-Württemberg. To enable it to produce fresh raw produce all year round, the company has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the complete product range could be supplied year-round, offered to end users throughout Germany through grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, as well as for third get together manufacturers. 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 greens and another arm for processing these products. As a household business, Gartenfrisch Jung has been handed from one technology to the subsequent ever since it began. The expertise gained as a result has due to this fact grown steadily, resulting in the company’s successful improvement and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food daily. This is equal to dealing with 2,000 pallets, which are then delivered to prospects 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 were 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 level prior to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continually throughout these shifts, aside from during breaks. During a third shift, the production facilities are cleaned while all equipment is stationary.
Jochen Neff, who’s in cost of technology at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, as a outcome of the heat radiated by the thirteen vacuum pumps was putting a strain on the air con system within the production services, 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 consultants from Busch Vacuum Solutions analyzed the state of affairs and recommended a centralized vacuum supply, which could be set up in a non-air-conditioned room outdoors the manufacturing amenities.
Because Jung’s convenience products have the ideal vacuum for packaging at a vacuum stage of four hundred millibars, Busch beneficial using MINK claw vacuum pumps. This sort of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which means that the transferring components inside the vacuum pump don’t come 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 rating of 8 kilowatts. However, one of the three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum provide enabled the total put in motor rating 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. maximum power. This would correspond to a 68 p.c discount in vitality consumption. However, in practice Jochen Neff has found that only one of many two MINK claw vacuum pumps is often in use and that this tends to run at a lowered rotational velocity. After several months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum provide. This is especially linked to the fact that the twelve packaging traces don’t all all the time run at most velocity and never the entire machines are in use on an everyday basis. The demand-based management system then decreases the rotational pace to reduce back the output, meaning that the system solely offers the performance that is actually required. In follow, this equates to vitality savings of over 90 percent for vacuum era.
The new centralized vacuum system was put in 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 be positive that the required vacuum stage is available within the packaging chambers as quickly as it’s needed within the packaging cycle. Removing the thirteen authentic vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air-con system might be turned down to hold the room temperature between 5 and 6 degrees Celsius. เกจวัดแรงดันน้ำมันเบนซิน in vitality costs on account of decreasing the air conditioning output have not been measured. However, it can typically be assumed that the change resulted in a big reduction within the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the individual MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance 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 highly energy-efficient, reliable and economical vacuum provide for packaging his convenience merchandise.
Fig: 1: One of twelve strains used to package 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 power 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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