Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market chief for recent comfort products due to 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 town in the German state of Baden-Württemberg. To allow it to produce contemporary uncooked produce all yr round, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the whole product vary can be provided year-round, sold to finish users throughout Germany by way of supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls underneath the company’s own label, in addition to for third celebration brands. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now remodeled into integrated, controlled growers of salads and greens and one other arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one generation to the next ever because it started. The experience gained as a result has therefore grown steadily, resulting in the company’s successful improvement and a high quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked food every single day. This is equivalent to dealing with 2,000 pallets, that are then delivered to customers by eighty refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the past, these packaging machines were outfitted 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 stage previous to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly all through these shifts, other than throughout breaks. During a third shift, the manufacturing facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in command of know-how at Gartenfrisch Jung, was on the lookout for an alternate vacuum provide, as a outcome of the warmth radiated by the thirteen vacuum pumps was putting a strain on the air conditioning system within the production services, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum consultants from Busch Vacuum Solutions analyzed the state of affairs and beneficial a centralized vacuum supply, which could be arrange in a non-air-conditioned room outdoors the manufacturing facilities.
Because Jung’s comfort merchandise have the ideal vacuum for packaging at a vacuum degree of four hundred millibars, Busch beneficial utilizing MINK claw vacuum pumps. This type of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free operating precept, which means that the moving components contained in the vacuum pump do not come in contact with each other. In turn, no oil-based lubrication is required and all maintenance work associated to the use 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 equipped with a motor with a nominal motor rating of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum provide enabled the whole put in motor score 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. most power. This would correspond to a 68 percent reduction in energy consumption. However, in follow Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational velocity. After a number of months of use, Jochen Neff has measured common power consumption of 4 kilowatt hours for the whole vacuum provide. This is principally linked to the reality that the twelve packaging strains don’t all at all times run at maximum pace and not the entire machines are in use on a regular basis. The demand-based control system then decreases the rotational pace to cut back the output, which means that the system only supplies the efficiency that’s really required. In practice, this equates to vitality financial savings of over 90 percent for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is linked to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make sure that the required vacuum stage is available in the packaging chambers as quickly as it’s needed in the packaging cycle. Removing เกจวัดแรงดันน้ำ10บาร์ from the production areas relieved strain from the air-con system. This meant that the air conditioning system could be turned down to maintain the room temperature between 5 and 6 degrees Celsius. The financial savings in power prices as a outcome of lowering the air-con output haven’t been measured. However, it may possibly usually be assumed that the change resulted in a big discount in the energy 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 manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is proscribed 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 highly energy-efficient, dependable and economical vacuum supply for packaging his convenience merchandise.
Fig: 1: One of twelve traces used to bundle convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the 2 vacuum vessels within the background
Fig. three: 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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