Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market chief for recent convenience products due to its high 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 convenience foods in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To permit it to provide contemporary uncooked produce all yr round, the corporate has its personal growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the complete product vary can be equipped year-round, offered to finish customers throughout Germany by way of supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls beneath the company’s own label, as nicely as for third celebration brands. Gartenfrisch Jung’s historical past dates back to 1795. What began out as a small piece of farmland has now transformed into built-in, controlled growers of salads and vegetables and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one era to the next ever since it started. The experience gained consequently has therefore grown steadily, leading to the company’s successful growth and a excessive quality normal of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked food every single day. This is equal to dealing with 2,000 pallets, which are then delivered to customers by 80 refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging strains with tray sealer packaging machines. In the previous, these packaging machines had been outfitted with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These thirteen vacuum pumps were 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 continually throughout these shifts, aside from throughout breaks. During a third shift, the manufacturing amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in command of know-how at Gartenfrisch Jung, was looking for an alternative vacuum provide, as a outcome of the heat radiated by the 13 vacuum pumps was putting a strain on the air-con system in the manufacturing facilities, that are cooled to between 5 and 6 levels 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 recommended a centralized vacuum provide, which might be set up in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s convenience merchandise have the perfect vacuum for packaging at a vacuum stage of four hundred millibars, Busch beneficial utilizing MINK claw vacuum pumps. This type of vacuum pump has the very best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which means that the shifting elements contained in the vacuum pump don’t come in contact with one another. In flip, no oil-based lubrication is required and all upkeep work associated to the use of oil as an working 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 ranking of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to make certain that all three vacuum pumps have the same number of operating hours.
Centralizing the vacuum supply enabled the whole installed motor ranking 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 vitality consumption. However, in follow Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational speed. After a number of months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the complete vacuum supply. This is especially linked to the reality that the twelve packaging strains do not all all the time run at most speed and never the entire machines are in use on a daily basis. The demand-based control system then decreases the rotational pace to reduce the output, which means that the system solely offers the performance that’s really required. In apply, this equates to energy financial savings of over ninety percent for vacuum technology.
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 through a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every ensure that the required vacuum level is on the market within the packaging chambers as quickly as it is needed within the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved pressure from the air con system. เกวัดแรงดันน้ำ meant that the air con system might be turned down to hold the room temperature between 5 and 6 degrees Celsius. The financial savings in power prices as a outcome of lowering the air conditioning output haven’t been measured. However, it can usually be assumed that the change resulted in a major 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 person MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is limited primarily 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 provide for packaging his convenience merchandise.
Fig: 1: One of twelve lines used to package comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the 2 vacuum vessels within the background
Fig. three: 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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