Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market leader for contemporary convenience merchandise thanks to its quality and experience. 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 convenience foods in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To allow it to produce recent uncooked produce all year round, the corporate has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the complete product vary may be supplied year-round, sold to end users throughout Germany via grocery store chains and low cost shops. The ready-to-eat salads are packaged into bowls beneath the company’s own label, as well as for third get together brands. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now remodeled into built-in, managed growers of salads and vegetables and one other arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one era to the subsequent ever because it started. The experience gained as a result has subsequently grown steadily, leading to the company’s successful growth and a excessive quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw meals every single day. This is equivalent to dealing with 2,000 pallets, which are then delivered to prospects by eighty 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 have been outfitted with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These thirteen 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 strains. The vacuum pumps ran continually throughout these shifts, apart from throughout breaks. During a 3rd shift, the manufacturing facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who is in charge of technology at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, because the heat radiated by the thirteen vacuum pumps was putting a strain on the air con system in the manufacturing 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 experts from Busch Vacuum Solutions analyzed the scenario and beneficial a centralized vacuum supply, which might be set up in a non-air-conditioned room outdoors the manufacturing services.
Because Jung’s convenience products have the ideal vacuum for packaging at a vacuum degree of four hundred millibars, Busch beneficial using MINK claw vacuum pumps. This type of vacuum pump has the best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which signifies that the transferring components contained in the vacuum pump do not come in contact with one another. In turn, no oil-based lubrication is required and all upkeep work associated to the usage 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 ranking of eight kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the same number of operating hours.
Centralizing the vacuum supply enabled the whole put in motor rating to be lowered from 50.2 to 16 kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. maximum energy. This would correspond to a 68 p.c reduction in energy consumption. However, in follow Jochen Neff has found that solely one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational velocity. After a number of months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the complete vacuum provide. This is mainly linked to the fact that the twelve packaging strains do not all at all times run at most velocity and never the entire machines are in use all the time. The demand-based management system then decreases the rotational velocity to scale back the output, meaning that the system solely supplies the performance that is actually required. In follow, this equates to vitality savings of over ninety 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 via a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every make positive that the required vacuum level is available in the packaging chambers as quickly as it is wanted within the packaging cycle. Removing the thirteen authentic vacuum pumps from the production areas relieved strain from the air conditioning system. This meant that the air-con system could be turned all the way down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in power costs on account of lowering the air-con output have not been measured. However, it might possibly usually be assumed that the change resulted in a significant discount in the power consumed by the air-con system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the person MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is restricted primarily to the annual preventive change in gear oil. This is performed by a Busch service technician. With pressure gauge ไฮ ด รอ ลิ ค centralized vacuum system, Jochen Neff has created a extremely energy-efficient, dependable and economical vacuum provide for packaging his convenience products.
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. three: Comparison of power consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020