Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market leader for fresh convenience merchandise thanks to its high quality and expertise. 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 contemporary facility in Jagsthausen, a city within the German state of Baden-Württemberg. To permit it to supply contemporary raw produce all 12 months spherical, the company has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the entire product range could be supplied year-round, offered to finish users across Germany through supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls beneath the company’s own label, as properly as for third celebration manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now reworked into built-in, controlled growers of salads and greens and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been passed from one technology to the subsequent ever because it began. The experience gained as a result has therefore grown steadily, leading to the company’s successful development and a high quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food every single day. This is equal to dealing with 2,000 pallets, which are then delivered to clients by 80 refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the previous, these packaging machines have been outfitted with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These 13 vacuum pumps have 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 traces. The vacuum pumps ran continuously all through these shifts, apart from throughout breaks. During a 3rd shift, the production amenities are cleaned whereas all machinery is stationary.
Jochen Neff, who’s in cost of expertise at Gartenfrisch Jung, was on the lookout for another vacuum provide, as a end result of the warmth radiated by the 13 vacuum pumps was placing a pressure on the air conditioning system in the manufacturing amenities, 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 consultants from Busch Vacuum Solutions analyzed the scenario and beneficial a centralized vacuum provide, which could be arrange in a non-air-conditioned room outside the manufacturing facilities.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum level of 400 millibars, Busch beneficial using MINK claw vacuum pumps. This sort of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which means that the moving elements contained in the vacuum pump don’t are available contact with each other. In flip, no oil-based lubrication is required and all upkeep work associated to the utilization 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 score of 8 kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the same number of operating hours.
Centralizing the vacuum supply enabled the whole 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 68 percent reduction in power consumption. However, in follow Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is often in use and that this tends to run at a lowered rotational pace. After several months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the entire vacuum provide. This is principally linked to the fact that the twelve packaging strains don’t all all the time run at maximum velocity and not all of the machines are in use on a daily basis. The demand-based management system then decreases the rotational pace to minimize back the output, which means that the system solely supplies the efficiency that is really required. In practice, this equates to vitality financial savings of over ninety percent for vacuum era.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is linked to the packaging machines via a network of pipelines. เกจวัดแรงดันpressuregauge with a quantity of 1,500 liters each make sure that the required vacuum stage is on the market within the packaging chambers as quickly as it’s wanted within the packaging cycle. Removing the thirteen authentic vacuum pumps from the production areas relieved pressure from the air conditioning system. This meant that the air-con system could be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The financial savings in energy prices because of decreasing the air conditioning output haven’t been measured. However, it may possibly typically be assumed that the change resulted in a big reduction within 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 during manufacturing and packaging. MINK claw vacuum pumps are practically 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 extremely energy-efficient, reliable and economical vacuum supply for packaging his comfort products.
Fig: 1: One of twelve lines used to bundle comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the 2 vacuum vessels within 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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