Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market chief for recent comfort products due to its quality and experience. Since early 2019, the vacuum provide to its tray sealer packaging machines has been exceptionally energy-efficient following the set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its convenience meals in a modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To permit it to produce contemporary uncooked produce all 12 months round, 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, offered to finish customers throughout Germany via grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, in addition to for third get together brands. Gartenfrisch Jung’s historical past dates back to 1795. What began out as a small piece of farmland has now reworked into integrated, managed growers of salads and vegetables and one other arm for processing these merchandise. As a household enterprise, Gartenfrisch Jung has been handed from one technology to the subsequent ever because it started. The expertise gained as a result has therefore grown steadily, resulting in the company’s profitable growth and a top quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food every day. This is equivalent to handling 2,000 pallets, which are then delivered to customers by eighty refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the past, these packaging machines had been geared up with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps had 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 strains. The vacuum pumps ran continually throughout these shifts, aside from during breaks. During a third shift, the production services are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in command of technology at Gartenfrisch Jung, was in search of another vacuum provide, because the heat radiated by the thirteen vacuum pumps was putting a strain on the air-con system within the production services, which are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the state of affairs and really helpful a centralized vacuum provide, which could probably be set up in a non-air-conditioned room outdoors the manufacturing amenities.
Because เกจวัดแรงดันราคา have the ideal vacuum for packaging at a vacuum level of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This sort of vacuum pump has the very best effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which signifies that the transferring components contained in the vacuum pump don’t come in contact with each other. In turn, no oil-based lubrication is required and all maintenance work related 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 outfitted with a motor with a nominal motor score of 8 kilowatts. However, one of many three vacuum pumps is completely 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 provide enabled the whole installed motor rating 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. maximum energy. This would correspond to a sixty eight p.c reduction in energy consumption. However, in follow Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a reduced rotational pace. After a number of months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the whole vacuum provide. This is principally linked to the fact that the twelve packaging lines do not all at all times run at maximum speed and not all of the machines are in use on an everyday basis. The demand-based control system then decreases the rotational velocity to reduce the output, which means that the system solely provides the performance that is actually required. In apply, this equates to energy financial savings of over 90 percent for vacuum generation.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is related to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every be positive that the required vacuum degree is available in the packaging chambers as quickly as it’s needed within the packaging cycle. Removing the thirteen original vacuum pumps from the manufacturing areas relieved strain from the air conditioning system. This meant that the air conditioning system might be turned right down to keep 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 typically be assumed that the change resulted in a major reduction in the power consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance can be carried out on the person 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 the centralized vacuum system, Jochen Neff has created a extremely energy-efficient, reliable and economical vacuum supply for packaging his comfort products.
Fig: 1: One of twelve strains used to package comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the two vacuum vessels within 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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