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Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market leader for contemporary convenience merchandise because of 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 meals in a modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To allow it to produce contemporary uncooked produce all yr round, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the entire product range may be provided year-round, sold to finish customers throughout Germany by way of grocery store chains and low cost shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third celebration manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now transformed into integrated, controlled growers of salads and greens and another arm for processing these merchandise. As a household business, Gartenfrisch Jung has been passed from one era to the subsequent ever since it began. The expertise gained consequently has therefore grown steadily, leading to the company’s successful development and a high quality standard of its products. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food every single day. This is equivalent to dealing with 2,000 pallets, that are then delivered to prospects by eighty refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines 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 thirteen vacuum pumps had been used to evacuate the trays to the required vacuum level previous to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran constantly all through these shifts, apart from throughout breaks. During a 3rd shift, the manufacturing facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in charge of technology at Gartenfrisch Jung, was looking for another vacuum supply, because the warmth radiated by the thirteen vacuum pumps was putting a pressure on the air con system in the manufacturing facilities, 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 experts from Busch Vacuum Solutions analyzed the state of affairs and really helpful a centralized vacuum provide, which could be arrange in a non-air-conditioned room exterior the production facilities.
Because Jung’s comfort merchandise have the ideal vacuum for packaging at a vacuum degree of four hundred millibars, Busch really helpful utilizing MINK claw vacuum pumps. This kind of vacuum pump has the best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which signifies that the shifting components inside the vacuum pump do not come in contact with one another. In flip, no oil-based lubrication is required and all upkeep work associated to using oil as an operating fluid is eradicated.
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 eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to guarantee that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum supply enabled the whole put in motor ranking 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 energy. This would correspond to a sixty eight % reduction in vitality consumption. However, in apply Jochen Neff has found that solely one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a lowered rotational speed. After several months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the whole vacuum supply. This is especially linked to the fact that the twelve packaging lines do not all always run at most speed and never the entire 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 supplies the efficiency that is actually required. In practice, this equates to energy financial savings of over ninety percent for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is connected to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every make positive that the required vacuum degree is available in the packaging chambers as soon as it is wanted within the packaging cycle. Removing เกจวัดความดันน้ำ from the production areas relieved pressure from the air conditioning system. This meant that the air conditioning system could possibly be turned right down to keep the room temperature between 5 and 6 degrees Celsius. The savings in power costs because of lowering the air con output haven’t been measured. However, it could typically be assumed that the change resulted in a major 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 individual MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are nearly 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 extremely energy-efficient, dependable and economical vacuum provide for packaging his convenience products.
Fig: 1: One of twelve traces used to bundle convenience 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 energy 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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