Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market chief for contemporary comfort merchandise due to its high quality and expertise. Since early 2019, the vacuum provide to its tray sealer packaging machines has been exceptionally energy-efficient following the installation of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its convenience foods in a modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To enable it to supply recent raw produce all year round, the company has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the complete product range can be provided year-round, bought to end users throughout Germany through grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls underneath the company’s own label, in addition to for third get together brands. เกจวัดแก๊สlpg to 1795. What started out as a small piece of farmland has now remodeled into integrated, controlled growers of salads and greens and another arm for processing these merchandise. As a family enterprise, Gartenfrisch Jung has been handed from one technology to the subsequent ever because it started. The experience gained in consequence has therefore grown steadily, leading to the company’s profitable development and a high quality standard of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw meals daily. This is equivalent to dealing with 2,000 pallets, that are then delivered to clients by 80 refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the previous, these packaging machines had been outfitted with one rotary vane vacuum pump every, though one machine had two vacuum pumps. These 13 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 traces. The vacuum pumps ran continually throughout these shifts, apart from during breaks. During a 3rd shift, the production facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in cost of know-how at Gartenfrisch Jung, was in search of an alternative vacuum provide, because the warmth radiated by the thirteen vacuum pumps was placing a strain on the air con system in the manufacturing amenities, which 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 situation and recommended a centralized vacuum supply, which might be set up in a non-air-conditioned room exterior the manufacturing services.
Because Jung’s comfort products have the ideal vacuum for packaging at a vacuum level of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This sort of vacuum pump has the very best efficiency factor out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which implies that the moving 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 working fluid is eliminated.
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 ranking of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to guarantee that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum supply enabled the entire put in 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 energy 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 decreased rotational speed. After a quantity of months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the whole vacuum provide. This is mainly linked to the truth that the twelve packaging traces do not all all the time run at maximum speed and never 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, meaning that the system only supplies the performance that’s truly required. In apply, this equates to power savings of over ninety percent 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 through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every ensure that the required vacuum degree is on the market in the packaging chambers as quickly as it is needed in the packaging cycle. Removing the thirteen original vacuum pumps from the production areas relieved strain from the air-con system. This meant that the air-con system could presumably be turned all the means down to hold the room temperature between 5 and 6 degrees Celsius. The financial savings in energy prices on account of lowering the air-con output haven’t been measured. However, it could typically be assumed that the change resulted in a significant reduction within the energy consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the individual MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is restricted 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 provide for packaging his comfort products.
Fig: 1: One of twelve strains used to package comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the 2 vacuum vessels in 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
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