Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market leader for contemporary convenience merchandise 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 town in the German state of Baden-Württemberg. To permit it to produce recent uncooked produce all yr round, the corporate has its personal growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the entire product vary can be supplied year-round, sold to finish users throughout Germany through grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, as well as for third get together manufacturers. Gartenfrisch Jung’s historical past dates again 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 products. As a family business, Gartenfrisch Jung has been handed from one generation to the next ever because it began. The expertise gained in consequence has therefore grown steadily, resulting in the company’s successful growth and a high quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals every single 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 strains with tray sealer packaging machines. In the past, these packaging machines were equipped 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 degree prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly throughout these shifts, aside from throughout breaks. During a 3rd shift, the production amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in management of expertise at Gartenfrisch Jung, was in search of an alternative vacuum supply, as a result of the warmth radiated by the thirteen vacuum pumps was placing a strain on the air conditioning system within the production amenities, 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 consultants from Busch Vacuum Solutions analyzed the situation and really helpful a centralized vacuum supply, which might be arrange in a non-air-conditioned room outside the manufacturing services.
Because Jung’s comfort products have the perfect vacuum for packaging at a vacuum stage of 400 millibars, Busch recommended using MINK claw vacuum pumps. This sort of vacuum pump has the highest efficiency issue out of all mechanical vacuum pumps. This is a result of their contact-free working precept, which implies that the moving components contained in the vacuum pump do not are available contact with one another. In flip, no oil-based lubrication is required and all upkeep work associated to using 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 8 kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum provide enabled the whole installed motor score to be lowered 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 68 % reduction in vitality consumption. However, in practice Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational pace. After several months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the complete vacuum provide. This is mainly linked to the fact that the twelve packaging lines do not all always run at most pace and never all of the machines are in use on an everyday basis. The demand-based control system then decreases the rotational pace to cut back the output, meaning that the system solely offers the performance that’s actually required. In practice, this equates to vitality savings of over 90 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 linked to the packaging machines by way of a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be sure that the required vacuum stage is on the market in the packaging chambers as soon as it is wanted in the packaging cycle. Removing the thirteen authentic vacuum pumps from the production areas relieved pressure from the air con system. เกจวัดแรงดันแก๊ส meant that the air conditioning system could probably be turned all the method down to hold the room temperature between 5 and 6 degrees Celsius. The savings in vitality costs as a end result of decreasing the air con output haven’t been measured. However, it could typically be assumed that the change resulted in a major discount within 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 throughout 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, reliable and economical vacuum supply for packaging his comfort merchandise.
Fig: 1: One of twelve strains used to package deal comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during 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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