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Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for recent convenience merchandise because of its high 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 foods in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To allow it to supply fresh raw produce all yr round, the corporate has its own growers in Germany and Portugal. Cultivation in two different climate zones ensures that the entire product range can be equipped year-round, bought to finish customers throughout Germany through supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third party brands. Gartenfrisch Jung’s historical past dates back to 1795. What began out as a small piece of farmland has now remodeled into built-in, controlled growers of salads and vegetables and one other arm for processing these products. As a family enterprise, Gartenfrisch Jung has been passed from one technology to the next ever since it started. The experience gained in consequence has subsequently grown steadily, resulting in the company’s profitable development and a prime quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw meals daily. This is equivalent to handling 2,000 pallets, that are then delivered to prospects 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 have 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 prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continually throughout these shifts, other than throughout breaks. During a 3rd shift, the production amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who is in command of technology at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, because the warmth radiated by the thirteen vacuum pumps was putting a pressure on the air conditioning system in the production amenities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the state of affairs and really helpful a centralized vacuum supply, which could be set up in a non-air-conditioned room exterior the production amenities.
Because Jung’s comfort merchandise have the perfect vacuum for packaging at a vacuum degree of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This kind of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free operating precept, which signifies that the moving elements inside the vacuum pump don’t are available in contact with each other. In flip, no oil-based lubrication is required and all upkeep work associated to the usage of oil as an operating fluid is eliminated.
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 rating of eight kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum provide enabled the total put in motor rating to be reduced from 50.2 to sixteen 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 percent discount in power consumption. However, in apply Jochen Neff has discovered that only one of many two MINK claw vacuum pumps is generally in use and that this tends to run at a reduced rotational speed. After a number of months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the entire vacuum provide. เกจวัดแรงดันน้ำประปาราคา is principally linked to the fact that the twelve packaging strains do not all all the time run at maximum pace and never all of the machines are in use all the time. The demand-based management system then decreases the rotational pace to scale back the output, that means that the system only supplies the performance that’s truly required. In apply, this equates to vitality savings of over ninety p.c for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is related to the packaging machines through a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every ensure that the required vacuum degree is on the market within the packaging chambers as soon as it is wanted in the packaging cycle. Removing the 13 original vacuum pumps from the production areas relieved strain from the air conditioning system. This meant that the air-con system could be turned right down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in power costs as a end result of reducing the air conditioning output haven’t been measured. However, it could typically be assumed that the change resulted in a significant discount in the vitality consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep 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 proscribed 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, dependable and economical vacuum provide for packaging his comfort merchandise.
Fig: 1: One of twelve strains used to package deal convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly 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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