เพรสเชอร์เกจ and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market chief for fresh convenience products 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 meals in a modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To allow it to produce fresh raw produce all 12 months spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the complete product range may be supplied year-round, sold to finish users across Germany via grocery store chains and discount stores. The ready-to-eat salads are packaged into bowls beneath the company’s own label, in addition to 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 integrated, managed growers of salads and greens and one other arm for processing these merchandise. As a household business, Gartenfrisch Jung has been passed from one era to the following ever since it started. The expertise gained consequently has therefore grown steadily, leading to the company’s successful improvement and a prime quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw food every single day. This is equivalent to dealing with 2,000 pallets, which are then delivered to clients by eighty refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the previous, these packaging machines have been 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 stage previous to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continually throughout these shifts, other than throughout breaks. During a 3rd shift, the manufacturing services are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in charge of technology at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, as a end result of the heat radiated by the thirteen vacuum pumps was placing a strain on the air-con system in the production 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 consultants from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum provide, which could presumably be set up in a non-air-conditioned room outdoors the manufacturing amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum level 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 operating principle, which implies that the moving components contained in the vacuum pump don’t are available in contact with each other. In flip, no oil-based lubrication is required and all upkeep work related to the utilization of oil as an working fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was geared up with a motor with a nominal motor rating of eight kilowatts. However, one of many three vacuum pumps is completely on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum supply enabled the whole installed motor ranking to be reduced from 50.2 to 16 kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. maximum power. This would correspond to a 68 p.c reduction in vitality consumption. However, in apply Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is generally in use and that this tends to run at a decreased rotational pace. After several months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the complete vacuum supply. This is principally linked to the truth that the twelve packaging strains don’t all all the time run at most velocity and never all of the machines are in use on an everyday basis. The demand-based management system then decreases the rotational velocity to reduce the output, meaning that the system only supplies the performance that is truly required. In practice, this equates to vitality savings of over 90 percent for vacuum era.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is connected to the packaging machines through a community of pipelines. ไดอะแฟรม with a volume of 1,500 liters every make sure that the required vacuum degree is available in the packaging chambers as soon as it is needed within the packaging cycle. Removing the 13 authentic vacuum pumps from the manufacturing areas relieved strain from the air con 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 vitality costs on account of reducing the air conditioning output haven’t been measured. However, it can usually be assumed that the change resulted in a major 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 practically maintenance-free. Maintenance is limited mainly to the annual preventive change in gear oil. This is performed 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 bundle convenience merchandise on tray sealers

Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the 2 vacuum vessels within the background

Fig. three: Comparison of energy consumption for a decentralized and centralized vacuum provide

Image rights: Busch Vacuum Solutions

Busch Vacuum Solutions

Global Marketing – Uli Merkle

10 March 2020