Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market chief for recent comfort products due to its 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 foods in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To allow it to supply recent uncooked produce all yr spherical, the company has its personal growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the complete product range could be provided year-round, bought to end users throughout Germany through grocery store chains and discount stores. The ready-to-eat salads are packaged into bowls under the company’s personal label, as well as for third celebration manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now transformed into built-in, managed growers of salads and vegetables and one other arm for processing these merchandise. As a household business, Gartenfrisch Jung has been handed from one generation to the next ever because it started. The experience gained as a result has subsequently grown steadily, leading to the company’s successful development and a prime quality commonplace of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked meals every day. This is equivalent to dealing with 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 lines with tray sealer packaging machines. In the previous, these packaging machines were equipped with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These 13 vacuum pumps have been used to evacuate the trays to the required vacuum stage prior to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran constantly throughout these shifts, other than throughout breaks. During a third shift, the manufacturing services are cleaned while all equipment is stationary.
Jochen Neff, who’s in command of know-how at Gartenfrisch Jung, was on the lookout for another vacuum supply, as a result of the heat radiated by the 13 vacuum pumps was placing a strain on the air-con system in the production amenities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the situation and really helpful a centralized vacuum provide, which could possibly be arrange in a non-air-conditioned room outdoors the manufacturing facilities.
Because Jung’s convenience merchandise have the perfect vacuum for packaging at a vacuum degree of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This kind of vacuum pump has the best effectivity factor out of all mechanical vacuum pumps. This is a result of their contact-free operating principle, which implies that the moving elements inside the vacuum pump do not are available contact with one another. In flip, no oil-based lubrication is required and all maintenance work related to the usage of oil as an operating fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was geared up with a motor with a nominal motor score of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to guarantee that all three vacuum pumps have the identical number of working hours.
Centralizing the vacuum supply enabled the total installed motor rating to be reduced from 50.2 to 16 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 discount in vitality consumption. However, in practice Jochen Neff has found that only one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a decreased rotational speed. After several months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum supply. This is principally linked to the fact that the twelve packaging lines don’t all always run at maximum velocity and not all of the machines are in use on an everyday basis. The demand-based management system then decreases the rotational speed to scale back the output, which means that the system solely provides the performance that is actually required. In practice, this equates to energy financial savings of over ninety p.c for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is related to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every make sure that the required vacuum level is on the market in the packaging chambers as soon as it is wanted in the packaging cycle. Removing the thirteen unique vacuum pumps from the production areas relieved strain from the air-con system. This meant that the air conditioning system could be turned down to keep the room temperature between 5 and 6 degrees Celsius. The financial savings in vitality costs because of decreasing the air-con output have not been measured. However, it can typically 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 can be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is proscribed primarily to the annual preventive change in gear oil. This is carried out by a Busch service technician. With ร้านซ่อมเครื่องวัดความดันomron centralized vacuum system, Jochen Neff has created a extremely energy-efficient, reliable and economical vacuum provide for packaging his comfort products.
Fig: 1: One of twelve traces used to package deal convenience merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two vacuum vessels within 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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