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 comfort products due to its quality and expertise. 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 modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to supply fresh uncooked produce all 12 months spherical, the company has its personal growers in Germany and Portugal. Cultivation in two different climate zones ensures that the whole product vary may be supplied year-round, sold to finish users across Germany through supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, in addition to for third get together manufacturers. Gartenfrisch Jung’s history dates back to 1795. What started 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 products. As a family enterprise, Gartenfrisch Jung has been handed from one era to the subsequent ever because it started. The experience gained as a result has due to this fact grown steadily, leading to the company’s successful improvement and a top quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw meals every day. This is equivalent to dealing with 2,000 pallets, that are then delivered to prospects by eighty refrigerated automobiles.
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 have 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 previous to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continuously throughout these shifts, aside from during breaks. During a 3rd shift, the manufacturing services are cleaned whereas all equipment is stationary.
Jochen Neff, who is in charge of technology at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, because the heat radiated by the thirteen vacuum pumps was placing a pressure on the air conditioning system in the manufacturing services, that are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum consultants from Busch Vacuum Solutions analyzed the scenario and really helpful a centralized vacuum provide, which might be arrange in a non-air-conditioned room outdoors the production amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum degree of 400 millibars, Busch recommended utilizing MINK claw vacuum pumps. This sort of vacuum pump has the best efficiency factor out of all mechanical vacuum pumps. เพชเชอร์เกจ is a results of their contact-free operating precept, which signifies that the transferring parts contained in the vacuum pump don’t are available in contact with one another. In turn, 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), every of which was equipped with a motor with a nominal motor rating 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 variety of operating hours.
Centralizing the vacuum supply enabled the total 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. most power. This would correspond to a 68 p.c discount in energy consumption. However, in follow Jochen Neff has discovered that only one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational pace. After several months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the whole vacuum supply. This is mainly linked to the reality that the twelve packaging traces don’t all always run at maximum speed and never all of the machines are in use all the time. The demand-based control system then decreases the rotational pace to cut back the output, meaning that the system only supplies the efficiency that is really required. In practice, this equates to energy savings of over ninety % for vacuum generation.
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 through a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every make sure that the required vacuum stage is out there within the packaging chambers as quickly as it is wanted in the packaging cycle. Removing the 13 unique vacuum pumps from the production areas relieved pressure from the air conditioning system. This meant that the air conditioning system might be turned right down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in energy costs on account of lowering the air con output have not been measured. However, เกจแรงดันลม may possibly generally be assumed that the change resulted in a significant discount within the power 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 during production and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is restricted primarily 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 strains used to package deal comfort 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 power consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020