Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit type a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market leader for contemporary comfort products due to its quality and expertise. Since early pressure gauge ลม , 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 convenience meals in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to supply recent raw produce all 12 months spherical, the company has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the entire product range can be equipped year-round, sold to end customers across Germany by way of supermarket chains and low cost stores. The ready-to-eat salads are packaged into bowls beneath the company’s own label, as well as for third celebration manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now reworked into built-in, managed growers of salads and greens and one other arm for processing these merchandise. As a household enterprise, Gartenfrisch Jung has been passed from one technology to the next ever because it began. The expertise gained consequently has due to this fact grown steadily, resulting in the company’s profitable growth and a high quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food every single day. This is equivalent to dealing with 2,000 pallets, which are then delivered to clients by 80 refrigerated vehicles.
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 equipped with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These thirteen vacuum pumps have 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 lines. The vacuum pumps ran continually all through these shifts, other than during breaks. During a third shift, the manufacturing amenities are cleaned while all machinery is stationary.
Jochen Neff, who is in charge of know-how at Gartenfrisch Jung, was looking for another vacuum supply, because the heat radiated by the thirteen vacuum pumps was putting a pressure on the air conditioning system in the production services, which are cooled to between 5 and 6 degrees 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 really helpful a centralized vacuum provide, which might be arrange in a non-air-conditioned room outside the production services.
Because Jung’s convenience merchandise have the perfect vacuum for packaging at a vacuum level of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This type of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which means that the transferring elements contained in the vacuum pump do not are available contact with one another. In flip, no oil-based lubrication is required and all upkeep work related 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), every of which was equipped with a motor with a nominal motor rating of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the identical number of working hours.
Centralizing the vacuum supply enabled the whole installed motor ranking to be lowered 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 68 % discount in vitality consumption. However, in follow Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational velocity. After a quantity of months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the whole vacuum supply. This is principally linked to the fact that the twelve packaging strains don’t all at all times run at most velocity and never all of the machines are in use all the time. The demand-based management system then decreases the rotational pace to cut back the output, meaning that the system only offers the performance that is actually required. In apply, this equates to vitality financial savings of over ninety p.c for vacuum era.
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 network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be positive that the required vacuum level is out there within the packaging chambers as quickly as it is needed in the packaging cycle. Removing the 13 unique vacuum pumps from the production areas relieved pressure from the air conditioning system. This meant that the air-con system could probably be turned right down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in vitality prices as a outcome of decreasing the air con output haven’t been measured. However, it may possibly generally be assumed that the change resulted in a major discount within the energy consumed by the air-con system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is limited 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 supply for packaging his comfort merchandise.
Fig: 1: One of twelve traces used to package deal convenience merchandise on tray sealers

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

Fig. three: Comparison of vitality 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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