Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit type a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market leader for fresh convenience merchandise 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 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 permit it to produce contemporary uncooked produce all yr round, the corporate has its personal growers in Germany and Portugal. เกจวัดแรงดันpressuregauge in two totally different climate zones ensures that the entire product range can be provided year-round, sold to finish customers across Germany through supermarket chains and discount stores. The ready-to-eat salads are packaged into bowls beneath the company’s personal label, in addition to for third party manufacturers. Gartenfrisch Jung’s history dates again to 1795. What started out as a small piece of farmland has now transformed into built-in, controlled growers of salads and greens and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one era to the subsequent ever since it started. The expertise gained in consequence has due to this fact grown steadily, resulting in the company’s successful improvement and a excessive quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw meals every day. This is equal to dealing with 2,000 pallets, which are then delivered to customers by eighty refrigerated autos.
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 were equipped with one rotary vane vacuum pump each, though one machine had two vacuum pumps. These 13 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 throughout these shifts, aside from during breaks. During a third shift, the manufacturing services are cleaned while all machinery is stationary.
Jochen Neff, who’s in cost of know-how at Gartenfrisch Jung, was looking for an alternate vacuum supply, because the warmth radiated by the thirteen vacuum pumps was putting a strain on the air conditioning system in the production facilities, 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 really helpful a centralized vacuum supply, which could be arrange in a non-air-conditioned room outdoors the manufacturing services.
Because Jung’s comfort products have the perfect vacuum for packaging at a vacuum level of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This sort of vacuum pump has the very best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which implies that the transferring elements inside the vacuum pump don’t are available contact with each other. In turn, no oil-based lubrication is required and all upkeep 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 outfitted with a motor with a nominal motor score of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the identical variety of operating hours.
Centralizing the vacuum supply enabled the entire installed motor score 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. maximum power. This would correspond to a 68 p.c discount in energy consumption. However, in practice Jochen Neff has found that solely one of many two MINK claw vacuum pumps is generally in use and that this tends to run at a decreased rotational velocity. After several months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the entire vacuum provide. This is principally linked to the truth that the twelve packaging traces do not all at all times run at most speed and never the entire machines are in use all the time. The demand-based management system then decreases the rotational velocity to minimize back the output, that means that the system solely offers the performance that’s truly required. In practice, this equates to power savings of over 90 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 volume of 1,500 liters every make certain that the required vacuum stage is on the market in the packaging chambers as soon as it’s needed within the packaging cycle. Removing the 13 original vacuum pumps from the manufacturing areas relieved pressure from the air-con system. This meant that the air conditioning system might be turned right down to hold the room temperature between 5 and 6 degrees Celsius. The savings in vitality prices because of lowering the air-con output have not been measured. However, it may possibly typically be assumed that the change resulted in a significant reduction within the energy 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 manufacturing and packaging. MINK claw vacuum pumps are almost 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 highly energy-efficient, dependable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve lines used to package comfort products 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 vitality consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020