Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market leader for recent comfort merchandise thanks 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 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 in the German state of Baden-Württemberg. To allow it to produce contemporary uncooked produce all yr spherical, the company has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the complete product range may be equipped year-round, sold to end users throughout Germany by way of supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls underneath the company’s own label, in addition to for third get together manufacturers. Gartenfrisch Jung’s history dates again to 1795. What started out as a small piece of farmland has now remodeled into built-in, managed growers of salads and vegetables and another arm for processing these merchandise. As a household enterprise, Gartenfrisch Jung has been handed from one technology to the next ever since it started. The experience gained consequently has subsequently grown steadily, leading to the company’s profitable growth and a top quality standard of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked food every day. This is equal to handling 2,000 pallets, which are then delivered to customers by 80 refrigerated vehicles.
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 had been outfitted with one rotary vane vacuum pump each, 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 constantly throughout these shifts, other than throughout breaks. During a 3rd shift, the production facilities are cleaned while all equipment is stationary.
Jochen Neff, who is in control of know-how at Gartenfrisch Jung, was on the lookout for an alternative vacuum provide, as a end result of the heat radiated by the 13 vacuum pumps was placing a pressure on the air-con system in the manufacturing facilities, 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 state of affairs and beneficial a centralized vacuum provide, which could probably be set up in a non-air-conditioned room outside the production services.
Because weksler ea14 have the perfect vacuum for packaging at a vacuum stage of four hundred millibars, Busch really helpful utilizing MINK claw vacuum pumps. This sort of vacuum pump has the highest effectivity factor out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which signifies that the moving elements contained in the vacuum pump do not are available in contact with each other. In turn, no oil-based lubrication is required and all maintenance work related to using 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 ranking 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 same variety of operating hours.
Centralizing the vacuum provide enabled the whole put in motor score 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. most energy. This would correspond to a 68 p.c reduction in power consumption. However, in follow Jochen Neff has found that solely 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 common power consumption of four kilowatt hours for the whole vacuum supply. This is mainly linked to the reality that the twelve packaging strains don’t all all the time run at maximum pace and not all of the machines are in use on a daily basis. The demand-based control system then decreases the rotational speed to reduce the output, which means that the system solely provides the performance that’s really required. In practice, this equates to vitality savings of over ninety % for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is related to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make certain that the required vacuum stage is on the market within the packaging chambers as quickly as it’s needed in the packaging cycle. Removing the thirteen authentic vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air-con system might be turned down to maintain the room temperature between 5 and 6 degrees Celsius. The savings in vitality costs as a end result of reducing the air-con output haven’t been measured. However, it might possibly generally 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, maintenance could be carried out on the person MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is restricted 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 supply for packaging his comfort merchandise.
Fig: 1: One of twelve strains used to package comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the two vacuum vessels in the background
Fig. 3: Comparison of power 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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