Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has advanced into the German market leader for recent comfort merchandise because of its quality and experience. 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 modern facility in Jagsthausen, a city within the German state of Baden-Württemberg. To allow it to provide contemporary uncooked produce all year spherical, the company has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the whole product range can be supplied year-round, bought to finish customers throughout Germany by way of grocery store chains and discount stores. The ready-to-eat salads are packaged into bowls underneath the company’s own label, in addition to for third celebration brands. Gartenfrisch Jung’s history dates back to 1795. What started out as a small piece of farmland has now reworked into integrated, managed growers of salads and vegetables and one other arm for processing these products. As a household business, Gartenfrisch Jung has been handed from one era to the next ever since it started. The expertise gained in consequence has therefore grown steadily, resulting in the company’s profitable growth and a excessive quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw food every day. This is equal 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 past, these packaging machines were outfitted with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 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 lines. The vacuum pumps ran constantly throughout these shifts, aside from throughout breaks. During a third shift, the manufacturing services are cleaned while all equipment is stationary.
Jochen Neff, who is in command of know-how at Gartenfrisch Jung, was on the lookout for an alternative vacuum provide, as a end result of the warmth radiated by the thirteen vacuum pumps was putting a pressure on the air conditioning system in the production 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 state of affairs and beneficial a centralized vacuum provide, which might be set up in a non-air-conditioned room exterior the manufacturing facilities.
Because Jung’s convenience merchandise have the ideal vacuum for packaging at a vacuum stage of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This sort of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which implies that the shifting parts inside the vacuum pump do not are available contact with one another. In weksler ea14 , no oil-based lubrication is required and all upkeep work related 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 eight kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to make certain that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum supply enabled the whole installed motor ranking 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. most power. This would correspond to a 68 % discount in energy consumption. However, in follow Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a lowered rotational speed. After several months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the whole vacuum provide. This is especially linked to the reality that the twelve packaging lines do not all all the time run at maximum velocity and not the entire machines are in use on an everyday basis. The demand-based management system then decreases the rotational pace to reduce the output, meaning that the system only provides the efficiency that is really required. In apply, this equates to vitality financial savings of over ninety % for vacuum generation.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines by way of a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every be positive that the required vacuum level is on the market within the packaging chambers as quickly as it’s needed in the packaging cycle. Removing the 13 original vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air conditioning system could possibly be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The financial savings in power costs on account of lowering the air-con output haven’t been measured. However, it can usually be assumed that the change resulted in a major reduction in the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the person MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are almost 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, dependable and economical vacuum supply for packaging his comfort merchandise.
Fig: 1: One of twelve traces used to package deal comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the 2 vacuum vessels in the background
Fig. 3: Comparison of vitality consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020