Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for fresh convenience products thanks to its high quality and expertise. Since early 2019, the vacuum provide 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 foods in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow xp2i to supply contemporary raw produce all yr round, the corporate has its personal growers in Germany and Portugal. Cultivation in two different climate zones ensures that the entire product vary could be provided year-round, offered to end customers throughout Germany via grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third get together manufacturers. Gartenfrisch Jung’s historical past dates back to 1795. What started out as a small piece of farmland has now transformed into integrated, managed growers of salads and greens and another arm for processing these products. As a family business, Gartenfrisch Jung has been handed from one generation to the next ever because it began. The experience gained in consequence has therefore grown steadily, resulting in the company’s successful improvement and a high quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food every day. This is equal to handling 2,000 pallets, that are then delivered to customers 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 had been equipped with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These thirteen vacuum pumps have 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 constantly all through these shifts, aside from during breaks. During a 3rd shift, the manufacturing facilities are cleaned while all equipment is stationary.
Jochen Neff, who’s in command of technology at Gartenfrisch Jung, was looking for an alternate vacuum supply, as a end result of the warmth radiated by the 13 vacuum pumps was placing a pressure on the air con system in the manufacturing services, which 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 state of affairs and recommended a centralized vacuum supply, which might be set up in a non-air-conditioned room exterior the production services.
Because Jung’s convenience products have the ideal vacuum for packaging at a vacuum degree of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This type of vacuum pump has the best efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free operating principle, which signifies that the shifting parts contained in the vacuum pump don’t are available in contact with one another. In flip, no oil-based lubrication is required and all maintenance work associated to the use of 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 equipped with a motor with a nominal motor rating of eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to guarantee that all three vacuum pumps have the same variety 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 energy. This would correspond to a 68 percent discount in energy consumption. However, in practice Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a lowered rotational pace. After a number of months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the complete vacuum provide. This is principally linked to the fact that the twelve packaging strains do not all always run at most pace and never all of the machines are in use on a daily basis. The demand-based control system then decreases the rotational pace to reduce back the output, which means that the system only provides the efficiency that is truly required. In apply, this equates to energy financial savings of over 90 percent for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use each 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 ensure that the required vacuum level is on the market within the packaging chambers as quickly as it’s needed in the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved pressure from the air-con system. This meant that the air con system could be turned down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in energy costs on account of lowering the air-con output haven’t been measured. However, it can typically be assumed that the change resulted in a significant discount in the power 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 proscribed 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 supply for packaging his comfort products.
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 2 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