Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for fresh comfort products thanks to its high quality and expertise. Since early 2019, the vacuum supply 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 meals in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to provide fresh uncooked produce all 12 months spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the entire product vary can be supplied year-round, bought to finish customers throughout Germany via supermarket chains and discount stores. The ready-to-eat salads are packaged into bowls beneath the company’s own label, in addition to for third party manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now remodeled into integrated, managed growers of salads and vegetables and one other arm for processing these products. As a household enterprise, Gartenfrisch Jung has been passed from one technology to the following ever because it started. The experience gained consequently has subsequently grown steadily, resulting in the company’s successful growth and a prime quality normal of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw meals every day. This is equal to dealing with 2,000 pallets, that are then delivered to clients 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 have been outfitted with one rotary vane vacuum pump every, though one machine had two vacuum pumps. These thirteen 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 lines. The vacuum pumps ran continuously throughout these shifts, other than during breaks. During a 3rd shift, the manufacturing facilities are cleaned whereas all machinery is stationary.
Jochen Neff, who is in control of know-how at Gartenfrisch Jung, was looking for another vacuum supply, as a outcome of the heat radiated by the 13 vacuum pumps was placing a pressure on the air conditioning system in the manufacturing amenities, 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 experts from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum provide, which could possibly be arrange in a non-air-conditioned room exterior the production services.
Because Jung’s convenience merchandise have the perfect vacuum for packaging at a vacuum stage of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This sort of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which signifies that the shifting parts contained in the vacuum pump do not are available in contact with one another. In turn, no oil-based lubrication is required and all upkeep work associated to using oil as an working fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was outfitted 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 guarantee that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum provide enabled the whole installed motor ranking to be decreased from 50.2 to 16 kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. maximum energy. This would correspond to a sixty eight percent reduction in power consumption. However, in practice Jochen Neff has discovered that only one of many two MINK claw vacuum pumps is often in use and that this tends to run at a lowered rotational speed. After several months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the whole vacuum provide. This is principally linked to the fact that the twelve packaging strains don’t all always run at most pace and not all the machines are in use all the time. The demand-based management system then decreases the rotational velocity to reduce back the output, which means that the system only offers the performance that’s truly required. In apply, this equates to power savings of over 90 p.c for vacuum era.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is linked to the packaging machines through a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be certain that the required vacuum degree is on the market in the packaging chambers as soon as it’s wanted within the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air conditioning system might be turned all the way down to hold the room temperature between 5 and 6 degrees Celsius. The savings in power prices on account of lowering the air-con output have not been measured. However, it could usually be assumed that the change resulted in a significant discount within the vitality consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the individual MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is restricted primarily to the annual preventive change in gear oil. This is performed by a Busch service technician. With เกจวัดแรงดันsumo 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 deal comfort products 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 provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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