Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market chief for fresh convenience products because of 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 contemporary uncooked produce all year spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the entire product range can be equipped year-round, offered to finish customers throughout Germany by way of grocery store chains and low cost 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 historical past dates back to 1795. What started out as a small piece of farmland has now transformed into integrated, controlled growers of salads and vegetables and another arm for processing these merchandise. As a household business, Gartenfrisch Jung has been handed from one generation to the next ever because it began. The experience gained in consequence has subsequently grown steadily, leading to the company’s profitable improvement and a prime quality normal of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked meals every day. This is equivalent to dealing with 2,000 pallets, that are then delivered to clients by 80 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 have been outfitted with one rotary vane vacuum pump every, although 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 strains. The vacuum pumps ran continuously throughout these shifts, apart from during breaks. During a 3rd shift, the manufacturing facilities are cleaned while all machinery is stationary.
Jochen Neff, who is in command of know-how at Gartenfrisch Jung, was in search of an alternate vacuum provide, as a result of the warmth radiated by the thirteen vacuum pumps was placing a strain on the air conditioning system within the manufacturing facilities, which 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 situation and really helpful a centralized vacuum supply, which might be set up in a non-air-conditioned room outdoors the manufacturing facilities.
Because Jung’s comfort merchandise have the ideal vacuum for packaging at a vacuum level of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This sort of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which signifies that the transferring elements inside the vacuum pump do not come in contact with each other. In flip, no oil-based lubrication is required and all maintenance work related 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 the three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to make sure that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum provide 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 power. This would correspond to a sixty eight percent discount in power consumption. However, in apply Jochen Neff has found that solely one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational pace. After a quantity of months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the complete vacuum supply. This is mainly linked to the reality that the twelve packaging lines do not all at all times run at maximum velocity and not all the machines are in use all the time. The demand-based control system then decreases the rotational pace to reduce back the output, meaning that the system solely offers the efficiency that is truly required. In follow, this equates to power savings of over ninety p.c for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use each since. เครื่องมือตรวจวัดความดันเลือดเรียกว่า is connected to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each ensure that the required vacuum level is out there within the packaging chambers as quickly as it is wanted within the packaging cycle. Removing the thirteen authentic vacuum pumps from the manufacturing areas relieved strain from the air con system. This meant that the air conditioning system could probably be turned down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in vitality costs as a end result of lowering the air conditioning output have not been measured. However, it could possibly generally 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 may be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is proscribed 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 highly energy-efficient, dependable and economical vacuum provide for packaging his comfort products.
Fig: 1: One of twelve lines used to bundle convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the two vacuum vessels in the background
Fig. 3: 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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