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Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market leader for fresh convenience products thanks to its 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 town within the German state of Baden-Württemberg. To allow it to provide recent uncooked produce all 12 months round, the corporate has its own growers in Germany and Portugal. Cultivation in two different climate zones ensures that the complete product vary may be provided year-round, sold to finish customers throughout Germany via supermarket chains and low cost stores. The ready-to-eat salads are packaged into bowls beneath the company’s personal label, in addition to for third get together brands. Gartenfrisch Jung’s history dates back to 1795. What started out as a small piece of farmland has now transformed into built-in, managed growers of salads and greens and one other arm for processing these products. As a household enterprise, Gartenfrisch Jung has been passed from one generation to the subsequent ever because it started. The experience gained in consequence has due to this fact grown steadily, leading to the company’s successful growth and a excessive quality commonplace of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked food every single day. This is equal to dealing with 2,000 pallets, which are then delivered to clients by 80 refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the past, these packaging machines were equipped with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These 13 vacuum pumps were 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 throughout these shifts, other than throughout breaks. During a 3rd shift, the manufacturing amenities are cleaned while all equipment is stationary.
Jochen Neff, who’s in cost of know-how at Gartenfrisch Jung, was on the lookout for an alternative vacuum provide, because the warmth radiated by the 13 vacuum pumps was placing a pressure on the air con system in the production amenities, 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 consultants from Busch Vacuum Solutions analyzed the scenario and really helpful a centralized vacuum provide, which could be set up in a non-air-conditioned room outdoors the manufacturing services.
Because Jung’s comfort products have the perfect vacuum for packaging at a vacuum stage of 400 millibars, Busch beneficial using MINK claw vacuum pumps. This type of vacuum pump has the very best efficiency issue out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which implies that the shifting elements contained in the vacuum pump don’t are obtainable in contact with each other. In flip, no oil-based lubrication is required and all upkeep work associated 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), each of which was outfitted 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 control system is programmed to ensure that all three vacuum pumps have the identical variety of working 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 68 % discount in vitality consumption. However, in practice Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational speed. After a quantity of months of use, Jochen Neff has measured common power consumption of 4 kilowatt hours for the complete vacuum supply. This is principally linked to the reality that the twelve packaging traces don’t all all the time run at maximum pace and not all the machines are in use on an everyday basis. The demand-based management system then decreases the rotational velocity to reduce back the output, meaning that the system solely supplies the performance that’s truly required. In practice, this equates to energy financial savings of over ninety p.c 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 via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be certain that the required vacuum level is available in the packaging chambers as quickly as it’s needed within the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved strain 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 power prices because of decreasing the air conditioning output haven’t been measured. However, it can usually be assumed that the change resulted in a big discount in the vitality consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is limited mainly to the annual preventive change in gear oil. เกจวัดแรงดันอากาศ is carried out by a Busch service technician. With the centralized vacuum system, Jochen Neff has created a extremely energy-efficient, reliable and economical vacuum provide for packaging his convenience products.
Fig: 1: One of twelve traces used to package deal comfort products 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 provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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