Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for recent comfort 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 meals in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to supply contemporary uncooked produce all 12 months spherical, the company has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the complete product vary may be equipped year-round, sold to end users throughout Germany through supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls beneath the company’s own label, in addition to for third celebration manufacturers. ราคาเกจวัดแรงดันลม to 1795. What began out as a small piece of farmland has now reworked into integrated, controlled growers of salads and vegetables and one other arm for processing these products. As a household business, Gartenfrisch Jung has been passed from one technology to the next ever because it started. The expertise gained consequently has therefore grown steadily, leading to the company’s profitable development and a high quality normal of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked food every day. This is equivalent to handling 2,000 pallets, which are then delivered to clients by 80 refrigerated vehicles.
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 had been equipped with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps have 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 constantly all through these shifts, apart from throughout breaks. During a third shift, the production facilities are cleaned while all machinery is stationary.
Jochen Neff, who is in command of know-how at Gartenfrisch Jung, was in search of an alternate vacuum supply, because the heat radiated by the 13 vacuum pumps was putting a pressure on the air con system within the manufacturing 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 scenario and recommended a centralized vacuum provide, which could be arrange in a non-air-conditioned room exterior the production amenities.
Because Jung’s convenience merchandise have the best vacuum for packaging at a vacuum level of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This kind of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a result of their contact-free operating precept, which signifies that the moving parts contained in the vacuum pump don’t are available in contact with each other. In turn, no oil-based lubrication is required and all upkeep work associated to the utilization 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 geared up with a motor with a nominal motor ranking of 8 kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the identical number of working hours.
Centralizing the vacuum supply enabled the total put in motor rating to be lowered from 50.2 to sixteen 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 vitality consumption. However, in apply Jochen Neff has found that only one of many two MINK claw vacuum pumps is generally in use and that this tends to run at a lowered rotational velocity. After a quantity of months of use, Jochen Neff has measured common power consumption of 4 kilowatt hours for the whole vacuum supply. This is mainly linked to the reality that the twelve packaging lines don’t all all the time run at maximum velocity and never all the machines are in use all the time. The demand-based management system then decreases the rotational pace to cut back the output, that means that the system solely provides the efficiency that is really required. In apply, this equates to vitality savings of over 90 % for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is related to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each be positive that the required vacuum stage is available in the packaging chambers as quickly as it’s needed within the packaging cycle. Removing เกจวัดความดันpressuregauge from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air con system could probably be turned right down to keep the room temperature between 5 and 6 levels Celsius. The savings in vitality prices because of reducing the air con output have not been measured. However, it can typically be assumed that the change resulted in a significant reduction in the power consumed by the air-con 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. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is restricted mainly 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, reliable and economical vacuum supply for packaging his convenience merchandise.
Fig: 1: One of twelve traces used to bundle comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the 2 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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