Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit type a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market chief for recent comfort products thanks to its high quality and experience. 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 comfort foods in a modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To allow it to provide recent raw produce all year round, the company has its own growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the entire product vary can be supplied year-round, bought to finish users throughout Germany via grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, in addition to for third celebration manufacturers. Gartenfrisch Jung’s history dates back to 1795. What began out as a small piece of farmland has now reworked into integrated, managed growers of salads and greens and one other arm for processing these merchandise. As a household business, Gartenfrisch Jung has been passed from one era to the next ever because it started. The experience gained as a result has subsequently grown steadily, resulting in the company’s profitable growth and a top quality standard of its products. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals every single day. เกจวัดแก๊ส is equivalent to handling 2,000 pallets, which are then delivered to prospects by 80 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 have been outfitted with one rotary vane vacuum pump each, though 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 traces. The vacuum pumps ran continuously throughout these shifts, other than during breaks. During a third shift, the manufacturing services are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in charge of know-how at Gartenfrisch Jung, was in search of another vacuum supply, as a outcome of the heat radiated by the thirteen vacuum pumps was placing a pressure on the air con system in the production facilities, which are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the scenario and beneficial a centralized vacuum provide, which might be arrange in a non-air-conditioned room exterior the manufacturing services.
Because Jung’s comfort merchandise have the perfect vacuum for packaging at a vacuum stage of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This type of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which signifies that the transferring components inside the vacuum pump do not come in contact with one another. In turn, no oil-based lubrication is required and all upkeep work related to the use of 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 equipped with a motor with a nominal motor score 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 number of operating hours.
Centralizing the vacuum supply enabled the total put in motor score to be lowered 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 sixty eight % reduction in energy consumption. However, in follow Jochen Neff has discovered that only one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a lowered 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 especially linked to the reality that the twelve packaging lines don’t all always run at most pace and not 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 solely provides the performance that is really required. In apply, this equates to vitality savings of over ninety p.c for vacuum era.
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 community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every make sure that the required vacuum degree is on the market in the packaging chambers as soon as it’s wanted in the packaging cycle. Removing the 13 unique vacuum pumps from the production areas relieved pressure from the air-con system. This meant that the air-con system could possibly be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The financial savings in energy prices on account of reducing the air conditioning output haven’t been measured. However, it could usually be assumed that the change resulted in a major reduction in the power consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are almost 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 highly energy-efficient, dependable and economical vacuum supply for packaging his comfort merchandise.
Fig: 1: One of twelve lines used to package convenience merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the 2 vacuum vessels within the background
Fig. 3: Comparison of energy 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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