Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market leader for recent convenience merchandise because of 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 modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To enable it to provide contemporary raw produce all year round, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the whole product range may be provided year-round, bought to finish users across Germany by way of grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls beneath the company’s own label, in addition to for third celebration brands. Gartenfrisch Jung’s history dates again to 1795. What started out as a small piece of farmland has now remodeled into integrated, managed growers of salads and greens and one other arm for processing these merchandise. As a family business, Gartenfrisch Jung has been passed from one technology to the next ever since it started. เกจวัดแรงดันเชื้อเพลิง gained consequently has therefore grown steadily, resulting in the company’s profitable growth and a high quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw food every single day. This is equivalent to dealing with 2,000 pallets, which are then delivered to customers by 80 refrigerated automobiles.
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 had been outfitted 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 degree previous to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continuously all through these shifts, apart from during breaks. During a third shift, the manufacturing services are cleaned while all equipment is stationary.
Jochen Neff, who’s in charge of technology at Gartenfrisch Jung, was looking for an alternate vacuum supply, as a result of the warmth radiated by the thirteen vacuum pumps was placing a strain on the air-con system in the manufacturing services, 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 scenario and recommended a centralized vacuum supply, which could be arrange in a non-air-conditioned room outside the production facilities.
Because Jung’s convenience merchandise have the perfect vacuum for packaging at a vacuum level of 400 millibars, Busch really helpful utilizing MINK claw vacuum pumps. This kind of vacuum pump has the very best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which means that the shifting parts inside the vacuum pump don’t are available contact with each other. In turn, no oil-based lubrication is required and all maintenance work associated to the utilization of 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 equipped with a motor with a nominal motor ranking of 8 kilowatts. However, one of many three vacuum pumps is exclusively 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 total installed motor rating to be lowered 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 % discount in energy consumption. However, in follow Jochen Neff has found that only one of the two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational speed. After several months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the complete vacuum provide. This is principally linked to the fact that the twelve packaging lines do not all all the time run at maximum pace and not the entire machines are in use all the time. The demand-based management system then decreases the rotational velocity to reduce the output, which means that the system only offers the performance that’s truly required. In apply, this equates to vitality savings of over 90 percent for vacuum generation.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is connected to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be certain that the required vacuum stage is out there within the packaging chambers as quickly as it’s needed in the packaging cycle. Removing the thirteen authentic vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air conditioning system could possibly be turned down to hold the room temperature between 5 and 6 degrees Celsius. The financial savings in vitality prices because of decreasing the air con output haven’t been measured. However, it could generally be assumed that the change resulted in a major reduction within the power 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 production and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is restricted 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 extremely energy-efficient, dependable and economical vacuum supply 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 during meeting with the two vacuum vessels in the background
Fig. three: Comparison of energy consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020

Latest Post