Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for fresh comfort products because of its quality and experience. Since early 2019, the vacuum provide 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 in the German state of Baden-Württemberg. To enable it to produce fresh raw produce all year spherical, the corporate has its personal growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the entire product vary could be supplied year-round, sold to finish customers throughout Germany via grocery store chains and discount stores. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third party manufacturers. Gartenfrisch Jung’s history dates back to 1795. What began out as a small piece of farmland has now transformed into built-in, controlled growers of salads and vegetables 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 started. The expertise gained in consequence has due to this fact grown steadily, leading to the company’s profitable development and a excessive quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw food every day. This is equal to handling 2,000 pallets, which are then delivered to clients by eighty refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the previous, these packaging machines were equipped 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 stage previous to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran constantly throughout these shifts, aside from during breaks. During a 3rd shift, the production amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who is in command of expertise at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, as a result of the warmth radiated by the 13 vacuum pumps was putting a strain on the air con system within the production amenities, 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 recommended a centralized vacuum supply, which might be arrange in a non-air-conditioned room exterior the production facilities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch really helpful using MINK claw vacuum pumps. This kind of vacuum pump has the very best effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free operating principle, which signifies that the transferring components contained in the vacuum pump do not are available contact with each other. In turn, no oil-based lubrication is required and all upkeep work related to the use of oil as an operating fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was outfitted with a motor with a nominal motor score of eight kilowatts. However, one of many three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum provide enabled the total put in 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. maximum energy. This would correspond to a 68 % discount in vitality consumption. However, in apply Jochen Neff has found that only one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational speed. After several months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the entire vacuum provide. This is especially linked to the reality that the twelve packaging lines do not all always run at maximum velocity and not the entire machines are in use on a regular basis. The demand-based control system then decreases the rotational velocity to scale back the output, meaning that the system solely supplies the efficiency that’s truly required. In practice, this equates to energy savings of over ninety p.c for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is connected to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be sure that the required vacuum level is out there in the packaging chambers as soon as it is wanted in the packaging cycle. Removing the thirteen original vacuum pumps from the manufacturing areas relieved strain from the air con system. This meant that the air conditioning system could be turned right down to maintain the room temperature between 5 and 6 degrees Celsius. The savings in vitality costs as a outcome of lowering the air conditioning output haven’t been measured. However, it could usually be assumed that the change resulted in a big discount in the power consumed by the air-con system.
nuova fima pressure gauge ราคา to the vacuum system’s redundant design, maintenance can be carried out on the individual MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is restricted 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, reliable and economical vacuum provide for packaging his convenience merchandise.
Fig: 1: One of twelve strains used to package convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two vacuum vessels within the background
Fig. 3: 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