Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market leader for fresh comfort merchandise because of its high quality and expertise. 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 comfort meals in a modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To allow it to supply contemporary uncooked produce all year spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the entire product vary can be supplied year-round, offered to finish users throughout Germany via supermarket 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 brands. Gartenfrisch Jung’s historical past dates again to 1795. What began 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 family enterprise, Gartenfrisch Jung has been passed from one era to the following ever since it started. pressure gauge ราคา ถูก gained consequently has therefore grown steadily, resulting in the company’s successful improvement and a excessive quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food daily. This is equal to handling 2,000 pallets, which 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 previous, these packaging machines had been geared up with one rotary vane vacuum pump each, though one machine had two vacuum pumps. These thirteen vacuum pumps have been 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 constantly all through these shifts, aside from during breaks. During a 3rd shift, the production services are cleaned while all equipment is stationary.
Jochen Neff, who is in command of technology at Gartenfrisch Jung, was in search of an alternate vacuum provide, as a result of the warmth radiated by the 13 vacuum pumps was placing a strain on the air con system within the production facilities, 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 specialists from Busch Vacuum Solutions analyzed the situation and beneficial a centralized vacuum supply, which might be set up in a non-air-conditioned room outside the production services.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum degree of four hundred millibars, Busch really helpful utilizing MINK claw vacuum pumps. This sort of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free working precept, which signifies that the transferring parts inside the vacuum pump do not come in contact with each other. In flip, no oil-based lubrication is required and all maintenance work associated to the usage of oil as an working fluid is eradicated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was equipped with a motor with a nominal motor score of eight kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to make certain that all three vacuum pumps have the same number of operating hours.
Centralizing the vacuum supply enabled the entire installed motor rating 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 sixty eight % discount in vitality consumption. However, in follow Jochen Neff has found that solely one of the two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational pace. After a quantity of months of use, Jochen Neff has measured average energy consumption of 4 kilowatt hours for the complete vacuum supply. This is mainly linked to the truth that the twelve packaging traces don’t all all the time run at most velocity and never all the machines are in use all the time. The demand-based control system then decreases the rotational speed to scale back the output, that means that the system only provides the efficiency that’s really required. In practice, this equates to vitality savings of over 90 % for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is linked to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make certain that the required vacuum degree is on the market within the packaging chambers as soon as it is needed within 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 could be turned down to maintain the room temperature between 5 and 6 degrees Celsius. The savings in power costs as a end result of decreasing the air-con output have not been measured. However, it may possibly typically be assumed that the change resulted in a big reduction in the energy consumed by the air-con system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the person 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 extremely energy-efficient, reliable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve traces used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the two vacuum vessels within the background
Fig. 3: 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

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