Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market chief for fresh comfort products due to its high quality and experience. 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 meals in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To permit it to provide fresh raw produce all 12 months round, the corporate has its personal growers in Germany and Portugal. เพรสเชอร์เกจnuovafima in two completely different local weather zones ensures that the complete product vary can be equipped year-round, bought to end users throughout Germany via grocery store chains and discount stores. The ready-to-eat salads are packaged into bowls beneath the company’s own label, in addition to for third party manufacturers. Gartenfrisch Jung’s history dates again to 1795. What started out as a small piece of farmland has now remodeled into built-in, managed growers of salads and vegetables and one other arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one era to the next ever since it started. The expertise gained as a result has subsequently grown steadily, leading to the company’s successful development and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food daily. This is equal to handling 2,000 pallets, which are then delivered to clients by 80 refrigerated autos.
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 had been geared up with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These thirteen vacuum pumps were used to evacuate the trays to the required vacuum level prior to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continually throughout these shifts, other than during breaks. During a 3rd shift, the production services are cleaned while all machinery is stationary.
Jochen Neff, who is in control of technology at Gartenfrisch Jung, was in search of an alternative vacuum provide, because the heat radiated by the 13 vacuum pumps was putting a pressure on the air conditioning system in the production 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 specialists from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum supply, which might be set up in a non-air-conditioned room outside the manufacturing amenities.
Because Jung’s comfort merchandise have the perfect vacuum for packaging at a vacuum level of four hundred millibars, Busch recommended using MINK claw vacuum pumps. This type of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free operating principle, which signifies that the transferring parts contained in the vacuum pump don’t come in contact with each other. In flip, no oil-based lubrication is required and all upkeep work related to the utilization of oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was equipped with a motor with a nominal motor ranking 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 same number of working hours.
Centralizing the vacuum supply enabled the entire installed motor score to be reduced from 50.2 to sixteen kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. maximum power. This would correspond to a sixty eight percent reduction in vitality consumption. However, in practice Jochen Neff has found that solely one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational speed. After a number of months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the complete vacuum provide. This is especially linked to the truth that the twelve packaging traces don’t all all the time run at maximum speed and not all the machines are in use all the time. The demand-based management system then decreases the rotational pace to reduce back the output, that means that the system only supplies the efficiency that’s really required. In follow, this equates to vitality financial savings of over 90 % 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 via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each ensure that the required vacuum stage is available in the packaging chambers as soon as it is wanted in the packaging cycle. Removing the thirteen unique vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air con system could be turned all the way down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in energy prices on account of lowering the air conditioning output have not been measured. However, it might possibly generally be assumed that the change resulted in a significant discount in the vitality consumed by the air-con system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the person MINK claw vacuum pumps throughout manufacturing 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 highly energy-efficient, reliable and economical vacuum provide for packaging his comfort merchandise.
Fig: 1: One of twelve strains 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. 3: 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
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