Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market leader for recent convenience merchandise because of its 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 city within the German state of Baden-Württemberg. To allow it to produce fresh raw produce all 12 months round, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the entire product vary may be provided year-round, sold to finish customers throughout Germany through grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls beneath the company’s personal label, as well as for third get together brands. Gartenfrisch Jung’s history dates back to 1795. What started out as a small piece of farmland has now reworked into integrated, managed growers of salads and greens and another arm for processing these merchandise. As a household business, Gartenfrisch Jung has been handed from one technology to the next ever since it began. The expertise gained consequently has due to this fact grown steadily, leading to the company’s successful development and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked food every day. This is equal to dealing with 2,000 pallets, that are then delivered to prospects by eighty refrigerated vehicles.
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 equipped with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These thirteen vacuum pumps were 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 continuously all through these shifts, other than during breaks. During a 3rd shift, the manufacturing amenities are cleaned while all equipment is stationary.
Jochen Neff, who is in command of know-how at Gartenfrisch Jung, was on the lookout for an alternative vacuum provide, as a result of the warmth radiated by the thirteen vacuum pumps was putting a pressure on the air-con system within the manufacturing services, which are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. เกจวัดแรงดันปั๊มลมpuma from Busch Vacuum Solutions analyzed the state of affairs and recommended a centralized vacuum provide, which might be arrange in a non-air-conditioned room outside the production facilities.
Because Jung’s comfort products have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch recommended using MINK claw vacuum pumps. This sort of vacuum pump has the highest effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which implies that the moving parts inside the vacuum pump do not come in contact with one another. In turn, no oil-based lubrication is required and all upkeep work associated to using oil as an operating 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 the three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum supply enabled the total put in motor ranking to be decreased from 50.2 to sixteen 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 the two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational pace. After a quantity of months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the complete vacuum provide. เกจวัดแรงดันต่ำ is mainly linked to the fact that the twelve packaging traces don’t all at all times run at maximum pace and not the entire machines are in use all the time. The demand-based control system then decreases the rotational velocity to reduce the output, which means that the system solely offers the performance that’s really required. In apply, this equates to energy savings of over 90 percent for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is linked to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every make certain that the required vacuum degree is available in the packaging chambers as soon as it is needed in the packaging cycle. Removing the thirteen original vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air-con system could be turned right down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in power prices on account of reducing the air con output have not been measured. However, it could possibly usually be assumed that the change resulted in a significant reduction in the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is limited 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, reliable and economical vacuum provide for packaging his convenience products.
Fig: 1: One of twelve lines used to package convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two vacuum vessels in the background
Fig. three: Comparison of vitality 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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