Enormous Energy Savings for Packaging Process

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 contemporary convenience merchandise 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 convenience foods in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To enable it to supply recent uncooked produce all year spherical, the company has its personal growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the whole product vary can be equipped year-round, sold to end customers throughout Germany via supermarket chains and low cost stores. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, as well as for third get together manufacturers. Gartenfrisch Jung’s history dates back to 1795. What began out as a small piece of farmland has now reworked into built-in, managed growers of salads and vegetables and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one technology to the subsequent ever because it began. The expertise gained consequently has due to this fact grown steadily, resulting in the company’s profitable improvement and a excessive quality standard of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food daily. This is equal to dealing with 2,000 pallets, that are then delivered to clients by 80 refrigerated autos.
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 had 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 level prior to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continuously throughout these shifts, other than during breaks. During a third shift, the production facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who is in command of expertise at Gartenfrisch Jung, was looking for another vacuum provide, as a outcome of the warmth radiated by the thirteen vacuum pumps was placing a strain on the air conditioning system within the manufacturing amenities, 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 state of affairs and recommended a centralized vacuum supply, which could be arrange in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s comfort products have the ideal vacuum for packaging at a vacuum stage of 400 millibars, Busch recommended utilizing MINK claw vacuum pumps. This sort of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which signifies that the transferring components contained in the vacuum pump do not are available contact with one another. In flip, no oil-based lubrication is required and all upkeep work related to the use 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 the three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same number of operating hours.
Centralizing the vacuum supply enabled the whole installed motor score to be lowered from 50.2 to sixteen 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 practice Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational speed. After several months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum supply. This is principally linked to the truth that the twelve packaging strains do not all at all times run at maximum pace and never the entire machines are in use all the time. The demand-based management system then decreases the rotational speed to cut back the output, that means that the system solely provides the performance that’s really required. In follow, this equates to energy savings of over 90 percent for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every 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 be sure that the required vacuum level is on the market in the packaging chambers as quickly as it is needed within the packaging cycle. Removing the 13 authentic vacuum pumps from the production areas relieved strain from the air conditioning system. This meant that the air con system might be turned down to keep the room temperature between 5 and 6 levels Celsius. The savings in power prices because of reducing the air conditioning output have not been measured. However, ราคาเพรสเชอร์เกจ might possibly usually 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 can be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is restricted 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 provide for packaging his comfort products.
Fig: 1: One of twelve lines used to bundle comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the two vacuum vessels in the background
Fig. three: 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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