Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market leader for contemporary convenience merchandise due to its high 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 meals in a modern facility in Jagsthausen, a city in the German state of Baden-Württemberg. To enable it to provide fresh raw produce all yr spherical, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the whole product vary may be supplied year-round, offered to end users across Germany through grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls under the company’s personal label, as properly as for third get together brands. Gartenfrisch Jung’s history dates back 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 products. As a family business, Gartenfrisch Jung has been passed from one generation to the following ever because it began. The experience gained in consequence has subsequently grown steadily, leading to the company’s profitable development and a prime quality normal of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food every single day. This is equal 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 past, these packaging machines have been equipped with one rotary vane vacuum pump each, though 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 continually all through these shifts, apart from during breaks. During a 3rd shift, the production amenities are cleaned while all equipment is stationary.
Jochen Neff, who is in command of technology at Gartenfrisch Jung, was in search of another vacuum provide, because the heat radiated by the 13 vacuum pumps was putting a pressure on the air-con system in the manufacturing facilities, that 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 specialists from Busch Vacuum Solutions analyzed the situation and really helpful a centralized vacuum provide, which could be set up in a non-air-conditioned room exterior the production amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum stage of four hundred millibars, Busch really helpful utilizing MINK claw vacuum pumps. This type of vacuum pump has the very best efficiency issue out of all mechanical vacuum pumps. This is a results of their contact-free operating precept, which implies that the transferring components inside the vacuum pump do not are obtainable 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 eradicated.
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 the three vacuum pumps is completely on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum supply enabled the total put in motor ranking 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 power. This would correspond to a 68 p.c discount in energy consumption. However, in apply 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 speed. After a quantity of months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the whole vacuum provide. This is mainly linked to the fact that the twelve packaging lines do not all always run at maximum velocity and never all of the machines are in use on a regular basis. The demand-based management system then decreases the rotational pace to reduce back the output, that means that the system solely offers the performance that’s truly required. In เกจวัดแรงดันco2 , this equates to vitality 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 connected to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be positive that the required vacuum level is on the market in the packaging chambers as soon as it is wanted in the packaging cycle. Removing the 13 original 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 maintain the room temperature between 5 and 6 degrees Celsius. The savings in energy costs because of reducing the air-con output have not been measured. However, it could generally be assumed that the change resulted in a big discount in the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is restricted 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 extremely energy-efficient, dependable and economical vacuum provide for packaging his convenience merchandise.
เกจวัดแรงดันไฟฟ้า : 1: One of twelve strains used to package deal comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the 2 vacuum vessels in the background
Fig. three: Comparison of vitality consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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