Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market leader for contemporary comfort 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 foods in a modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To allow it to provide recent raw produce all yr spherical, the corporate 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, sold to finish users across Germany via grocery store chains and low cost shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, as nicely as for third celebration manufacturers. Gartenfrisch Jung’s history dates again to 1795. What started out as a small piece of farmland has now remodeled into integrated, managed growers of salads and greens and one other arm for processing these merchandise. As a household business, Gartenfrisch Jung has been passed 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 successful development and a top quality normal of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food every single day. This is equivalent to handling 2,000 pallets, which are then delivered to prospects by eighty refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging strains with tray sealer packaging machines. In the previous, these packaging machines had been geared up 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 stage prior 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 during breaks. During a 3rd shift, the production facilities are cleaned while all machinery is stationary.
Jochen Neff, who’s in command of know-how at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, as a result of the heat radiated by the 13 vacuum pumps was placing a pressure on the air conditioning system within the production amenities, 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 scenario and really helpful a centralized vacuum provide, which could possibly be set up in a non-air-conditioned room outside the manufacturing services.
Because Jung’s convenience products have the best vacuum for packaging at a vacuum level of 400 millibars, Busch recommended using MINK claw vacuum pumps. This kind of vacuum pump has the highest effectivity factor out of all mechanical vacuum pumps. เครื่องมือที่ใช้วัดความดันโลหิต is a result of their contact-free operating principle, which signifies that the transferring parts contained in the vacuum pump do not are available contact with one another. In turn, no oil-based lubrication is required and all upkeep work associated to using oil as an operating fluid is eradicated.
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 score of eight kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to guarantee that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum supply enabled the entire installed motor ranking 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. most power. This would correspond to a 68 p.c reduction in power consumption. However, in apply 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 decreased rotational speed. After several months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the whole vacuum provide. This is mainly linked to the fact that the twelve packaging strains do not all at all times run at most velocity and not all the machines are in use on an everyday basis. The demand-based management system then decreases the rotational speed to scale back the output, that means that the system solely offers the efficiency that is truly required. In follow, this equates to energy savings of over ninety % for vacuum generation.
The new centralized vacuum system was put in 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 every be sure that the required vacuum degree is on the market in the packaging chambers as quickly as it is wanted in the packaging cycle. Removing the thirteen unique vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air-con system could be turned down to keep the room temperature between 5 and 6 degrees Celsius. The savings in vitality prices because of decreasing the air con output have not been measured. However, it can generally be assumed that the change resulted in a significant discount in the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the person MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is limited 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 supply for packaging his comfort products.
Fig: 1: One of twelve lines used to package comfort products on tray sealers

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

Fig. 3: 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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