Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market chief for contemporary comfort merchandise due to its high quality and expertise. 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 convenience meals in a modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To allow it to provide contemporary uncooked produce all year round, the company has its own growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the complete product range may be equipped year-round, sold to finish users throughout Germany through grocery store chains and low cost shops. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, in addition to for third party manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What began 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 products. As a family business, Gartenfrisch Jung has been passed from one era to the subsequent ever since it started. The expertise gained consequently has therefore grown steadily, leading to the company’s profitable growth and a top quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw meals every day. This is equivalent to handling 2,000 pallets, that are then delivered to clients by eighty refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the past, these packaging machines were 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 prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continually all through these shifts, apart from during breaks. During a 3rd shift, the manufacturing services are cleaned while all equipment is stationary.
Jochen Neff, who is in management of technology at Gartenfrisch Jung, was looking for another vacuum provide, as a outcome of the heat radiated by the 13 vacuum pumps was placing a strain on the air conditioning system in the production amenities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum consultants from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum supply, which could presumably be set up in a non-air-conditioned room outside the production services.
Because Jung’s convenience merchandise have the ideal vacuum for packaging at a vacuum stage of 400 millibars, Busch really helpful utilizing MINK claw vacuum pumps. This kind of vacuum pump has the very best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which implies that the transferring elements contained in the vacuum pump do not are available contact with one another. In flip, no oil-based lubrication is required and all upkeep work associated to the utilization of oil as an operating fluid is eliminated.
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 the 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 provide enabled the total put in 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. most energy. This would correspond to a 68 percent discount in power consumption. However, in practice Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational velocity. After a quantity of months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum supply. This is mainly linked to the fact that the twelve packaging strains don’t all always run at maximum pace and not all the machines are in use all the time. The demand-based control system then decreases the rotational speed to scale back the output, meaning that the system solely offers the performance that is actually required. In practice, this equates to power financial savings of over ninety percent for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is linked to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make positive that the required vacuum stage is available in the packaging chambers as soon as it’s needed in the packaging cycle. Removing the 13 unique 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 hold the room temperature between 5 and 6 levels Celsius. The savings in energy prices as a result of reducing the air-con output haven’t been measured. However, it could usually be assumed that the change resulted in a big discount within the energy consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the person MINK claw vacuum pumps during manufacturing and packaging. เกจวัดแรงดัน are practically maintenance-free. Maintenance is proscribed 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, reliable and economical vacuum provide for packaging his comfort merchandise.
Fig: 1: One of twelve lines used to package deal comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two vacuum vessels within 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