Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit type a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market leader for contemporary convenience merchandise 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 foods in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To permit it to provide fresh uncooked produce all 12 months round, the company has its personal growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the complete product range can be equipped year-round, sold to end users across Germany through supermarket chains and low cost stores. The ready-to-eat salads are packaged into bowls beneath the company’s own label, as properly as 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 greens and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one technology to the next ever because it began. The expertise gained in consequence has therefore grown steadily, resulting in the company’s profitable improvement and a high quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food every day. This is equivalent to dealing with 2,000 pallets, which are then delivered to customers by eighty refrigerated vehicles.
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 have been geared up with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps had been used to evacuate the trays to the required vacuum level prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continuously all through these shifts, apart from throughout breaks. During a 3rd shift, the production services are cleaned whereas all machinery is stationary.
Jochen Neff, who is in cost of expertise at Gartenfrisch Jung, was looking for an alternate vacuum supply, as a outcome of the heat radiated by the 13 vacuum pumps was putting a strain on the air con system within the manufacturing facilities, that 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 situation and recommended a centralized vacuum provide, which could presumably be arrange in a non-air-conditioned room outdoors the production facilities.
Because Jung’s convenience merchandise have the ideal vacuum for packaging at a vacuum stage of 400 millibars, Busch really helpful utilizing MINK claw vacuum pumps. This kind of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which means that the transferring elements inside the vacuum pump do not are out there in contact with one another. In flip, no oil-based lubrication is required and all maintenance work related to using oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was geared up with a motor with a nominal motor score of 8 kilowatts. However, one of the three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to guarantee that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum supply enabled the total 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. maximum energy. This would correspond to a sixty eight percent reduction in power consumption. However, in apply Jochen Neff has found that only one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational velocity. After several months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the complete vacuum provide. pressure gauge ยี่ห้อ tk is principally linked to the reality that the twelve packaging lines do not all always run at maximum speed and not all of the machines are in use on a daily basis. The demand-based control system then decreases the rotational pace to reduce the output, that means that the system only offers the efficiency that’s really required. In apply, this equates to vitality financial savings of over ninety % for vacuum generation.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is related to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every ensure that the required vacuum degree is out there within the packaging chambers as soon as it is wanted within the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air-con system could be turned down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in power costs on account of reducing the air con output have not been measured. However, it could generally be assumed that the change resulted in a big reduction within the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance can be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is proscribed mainly 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, reliable and economical vacuum supply for packaging his comfort products.
Fig: 1: One of twelve traces used to package convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the two vacuum vessels within the background
Fig. three: 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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