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 chief for recent comfort merchandise thanks to its high quality and experience. 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 town in the German state of Baden-Württemberg. To permit it to provide contemporary raw produce all yr spherical, the company has its own growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the entire product vary could be supplied year-round, bought to end customers across Germany by way of grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, as properly as for third party brands. Gartenfrisch Jung’s historical past dates again to 1795. What began out as a small piece of farmland has now transformed into integrated, managed growers of salads and greens and another arm for processing these products. As a household business, Gartenfrisch Jung has been passed from one generation to the following ever because it started. The experience gained consequently has due to this fact grown steadily, leading to the company’s successful improvement and a high quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw meals every day. This is equal to dealing with 2,000 pallets, that are then delivered to clients 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 past, these packaging machines were geared up with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These thirteen 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 lines. The vacuum pumps ran continually all through these shifts, apart from throughout breaks. During a third shift, the manufacturing services are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in control of technology 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 pressure on the air con system in the manufacturing 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 beneficial a centralized vacuum supply, which could be set up in a non-air-conditioned room outdoors the production amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch really helpful utilizing MINK claw vacuum pumps. This type 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 signifies that the moving elements contained in the vacuum pump don’t are obtainable in contact with one another. In flip, no oil-based lubrication is required and all upkeep 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 outfitted with a motor with a nominal motor ranking of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the same number of working hours.
Centralizing เกจวัดแรงดันน้ำประปาราคา enabled the total put in motor ranking 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 energy. This would correspond to a sixty eight p.c discount in energy consumption. However, in apply 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 reduced rotational speed. After a quantity of months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the whole vacuum supply. This is mainly linked to the reality that the twelve packaging traces do not all all the time run at most velocity and not all the machines are in use on an everyday basis. The demand-based control system then decreases the rotational velocity to reduce the output, meaning that the system solely provides the efficiency that is actually required. In apply, this equates to power financial 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. It is linked to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each ensure that the required vacuum degree is on the market in the packaging chambers as soon as it’s wanted in the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved strain from the air-con system. This meant that the air conditioning system could be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The savings in energy prices as a result of lowering the air con output haven’t been measured. However, it might possibly usually be assumed that the change resulted in a big discount within the energy 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 proscribed mainly 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 convenience merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the two vacuum vessels in the background
Fig. 3: Comparison of power consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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