Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market leader for recent convenience products due to its quality and experience. Since early 2019, the vacuum supply 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 comfort foods in a modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To enable it to provide fresh uncooked produce all 12 months round, the company has its personal growers in Germany and Portugal. เกจวัดแรงดันแก๊ส in two completely different local weather zones ensures that the whole product vary may be provided year-round, bought to finish users throughout Germany through grocery store chains and low cost shops. The ready-to-eat salads are packaged into bowls underneath the company’s own label, as properly as for third get together manufacturers. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now remodeled into integrated, controlled growers of salads and vegetables and another arm for processing these products. As a family enterprise, Gartenfrisch Jung has been handed from one technology to the following ever since it started. The expertise gained as a result has subsequently grown steadily, leading to the company’s successful growth and a high quality normal of its products. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw food every day. This is equal to handling 2,000 pallets, which are then delivered to prospects 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 geared up with one rotary vane vacuum pump every, though 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 lines. The vacuum pumps ran continually all through these shifts, other than throughout breaks. During a third shift, the manufacturing amenities are cleaned whereas all machinery is stationary.
Jochen Neff, who is in charge of know-how at Gartenfrisch Jung, was on the lookout for another vacuum supply, as a end result of the warmth radiated by the 13 vacuum pumps was placing a strain on the air con system in 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. เพรสเชอร์เกจ4นิ้ว from Busch Vacuum Solutions analyzed the situation and beneficial a centralized vacuum provide, which could presumably be arrange in a non-air-conditioned room exterior the manufacturing facilities.
Because Jung’s comfort products have the ideal vacuum for packaging at a vacuum stage of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This sort of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free operating precept, which signifies that the moving elements contained in the vacuum pump do not come in contact with each other. In flip, no oil-based lubrication is required and all upkeep work related to using oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was geared up with a motor with a nominal motor score of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to guarantee that all three vacuum pumps have the same variety of operating hours.
Centralizing the vacuum provide enabled the total put in motor rating to be decreased 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 68 percent discount in energy consumption. However, in follow Jochen Neff has discovered that only one of many two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational velocity. After a number of months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the complete vacuum supply. This is principally linked to the truth that the twelve packaging lines don’t all all the time run at maximum pace and never all the machines are in use all the time. The demand-based management system then decreases the rotational pace to reduce the output, meaning that the system only provides the performance that is actually required. In apply, this equates to energy financial savings of over 90 p.c for vacuum era.
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 network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each ensure that the required vacuum degree is out there within the packaging chambers as soon as it is needed in the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air conditioning system could probably be turned all the way down to maintain the room temperature between 5 and 6 degrees Celsius. The financial savings in power prices on account of lowering the air-con output have not been measured. However, it could typically be assumed that the change resulted in a major discount within the energy consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep may be carried out on the person MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is proscribed 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 highly energy-efficient, dependable and economical vacuum supply for packaging his comfort merchandise.
Fig: 1: One of twelve lines used to bundle convenience merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the two vacuum vessels in the background
Fig. 3: Comparison of vitality 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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