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Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit type a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has evolved into the German market chief for contemporary convenience merchandise due to its 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 foods in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to produce recent uncooked produce all 12 months spherical, the corporate has its personal growers in Germany and Portugal. Cultivation in two different climate zones ensures that the whole product vary could be equipped year-round, offered to end customers across Germany by way of supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls beneath the company’s personal label, as well as for third get together manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now remodeled into integrated, managed growers of salads and vegetables and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been passed from one technology to the next ever since it started. The expertise gained in consequence has therefore grown steadily, leading to the company’s successful growth and a high quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked meals daily. This is equal to handling 2,000 pallets, which are then delivered to prospects by eighty refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the previous, these packaging machines had been outfitted 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 stage previous 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 amenities are cleaned while all machinery is stationary.
Jochen Neff, who’s in management of expertise at Gartenfrisch Jung, was on the lookout for an alternative vacuum supply, because the warmth radiated by the thirteen vacuum pumps was placing a strain on the air conditioning system in the manufacturing facilities, that 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 scenario and recommended a centralized vacuum provide, which could be set up in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch beneficial utilizing MINK claw vacuum pumps. This sort of vacuum pump has the best efficiency issue out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which implies that the moving elements inside the vacuum pump do not are obtainable in contact with each other. In flip, no oil-based lubrication is required and all maintenance work associated to using oil as an operating 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 rating of eight kilowatts. However, one of many three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to guarantee that all three vacuum pumps have the identical variety of operating hours.
Centralizing the vacuum supply enabled the whole installed motor score 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. most energy. This would correspond to a sixty eight p.c discount in power consumption. However, in follow Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational speed. After a number of months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum provide. This is mainly linked to the reality that the twelve packaging traces don’t all at all times run at maximum speed and never all the machines are in use on a regular basis. เกจวัดแรงดันอากาศ -based management system then decreases the rotational speed to scale back the output, that means that the system solely supplies the performance that is really required. In apply, this equates to power financial savings of over ninety p.c for vacuum technology.
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 via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be certain that the required vacuum stage is available within the packaging chambers as soon as it’s needed within the packaging cycle. Removing the 13 original vacuum pumps from the production areas relieved strain from the air con system. This meant that the air con system might be turned all the way down to maintain the room temperature between 5 and 6 degrees Celsius. The savings in energy prices as a end result of lowering the air-con output haven’t been measured. However, it could usually be assumed that the change resulted in a big discount in the energy consumed by the air-con system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is limited primarily 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, reliable and economical vacuum provide for packaging his convenience products.
Fig: 1: One of twelve strains used to package comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the 2 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
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