Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market chief for recent convenience merchandise due to its quality and expertise. 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 supply fresh raw produce all 12 months round, the corporate has its own growers in Germany and Portugal. Cultivation in two different climate zones ensures that the whole product range may be supplied year-round, sold to finish customers across Germany via grocery store 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 party manufacturers. 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 enterprise, Gartenfrisch Jung has been handed from one technology to the following ever because it started. The expertise gained as a result has subsequently grown steadily, leading to the company’s successful improvement and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked food daily. This is equivalent to handling 2,000 pallets, which are then delivered to customers 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 equipped with one rotary vane vacuum pump every, though 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, aside from throughout breaks. During a third shift, the production amenities are cleaned whereas all machinery is stationary.
Jochen Neff, who is in cost of know-how at Gartenfrisch Jung, was looking for an alternative vacuum provide, because the heat radiated by the 13 vacuum pumps was putting a strain on the air con system in the manufacturing services, that 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 specialists from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum supply, which could presumably be set up in a non-air-conditioned room outside the manufacturing amenities.
Because Jung’s comfort products have the best vacuum for packaging at a vacuum stage of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This sort of vacuum pump has the best efficiency factor out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which implies that the shifting elements contained in the vacuum pump do not come in contact with one another. In flip, 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 geared up with a motor with a nominal motor rating of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to make sure that all three vacuum pumps have the same variety of operating hours.
Centralizing the vacuum supply enabled the entire installed 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 68 percent discount in energy consumption. However, in เกจวัดแรงดันออกซิเจนราคา has found that solely one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational speed. After several months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the whole vacuum supply. This is especially linked to the truth that the twelve packaging strains don’t all at all times run at most speed and not all of the machines are in use all the time. The demand-based control system then decreases the rotational speed to scale back the output, which means that the system solely offers the performance that is truly required. In practice, this equates to energy savings of over 90 p.c for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is connected to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each ensure that the required vacuum stage is available in the packaging chambers as soon as it’s needed within the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved strain from the air-con system. This meant that the air-con system could presumably be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The financial savings in power costs on account of lowering the air con output haven’t been measured. However, it could possibly usually be assumed that the change resulted in a major reduction in the vitality 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 manufacturing and packaging. MINK claw vacuum pumps are practically maintenance-free. ร้านซ่อมเครื่องวัดความดัน is limited 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 extremely energy-efficient, reliable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve lines used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the two vacuum vessels in 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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