Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market chief for recent comfort products due to its quality and experience. 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 convenience meals in a modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To enable it to produce contemporary uncooked produce all yr round, the company has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the entire product vary may be supplied year-round, bought to end customers across Germany through supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s own label, in addition to for third get together brands. เกจวัดแรงดันดิจิตอลราคา to 1795. What began out as a small piece of farmland has now reworked into integrated, 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 era to the following ever since it began. The expertise gained in consequence has therefore grown steadily, leading to the company’s successful improvement and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked food every single day. This is equal to dealing with 2,000 pallets, that are then delivered to clients by eighty refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the past, these packaging machines had been geared up with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps were 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 throughout these shifts, aside from throughout breaks. During a 3rd shift, the manufacturing facilities are cleaned while all machinery is stationary.
Jochen Neff, who’s in cost of know-how at Gartenfrisch Jung, was in search of another vacuum supply, because the heat radiated by the thirteen vacuum pumps was putting a strain on the air-con 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 specialists from Busch Vacuum Solutions analyzed the scenario and recommended a centralized vacuum supply, which could presumably be arrange in a non-air-conditioned room outside the manufacturing services.
Because Jung’s convenience merchandise have the best vacuum for packaging at a vacuum stage of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This kind of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free operating principle, which signifies that the moving components inside the vacuum pump don’t come in contact with each other. In flip, no oil-based lubrication is required and all maintenance work associated to the use of oil as an working fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was outfitted with a motor with a nominal motor score of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the identical number of working hours.
Centralizing the vacuum provide enabled the entire installed motor ranking to be reduced 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 p.c discount in vitality consumption. However, in follow Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a reduced rotational pace. After several months of use, Jochen Neff has measured average energy consumption of 4 kilowatt hours for the entire vacuum supply. This is principally linked to the fact that the twelve packaging strains do not all at all times run at most velocity and not all of the machines are in use on an everyday basis. The demand-based control system then decreases the rotational pace to reduce the output, that means that the system only provides the efficiency that is truly required. In practice, this equates to power savings of over 90 % for vacuum generation.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every make certain that the required vacuum level is on the market within the packaging chambers as quickly as it’s needed in the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air-con system could be turned right down to maintain the room temperature between 5 and 6 degrees Celsius. The financial savings in power costs on account of lowering the air-con output have not been measured. However, it can usually be assumed that the change resulted in a big reduction in the power consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep could 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 performed by a Busch service technician. With the centralized vacuum system, Jochen Neff has created a extremely energy-efficient, dependable and economical vacuum supply for packaging his comfort merchandise.
Fig: 1: One of twelve lines used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during 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