Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit type a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for fresh comfort merchandise because of its quality and experience. 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.
เกจ์ออกซิเจนsumo produces its convenience foods in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to supply recent uncooked produce all year spherical, the company has its personal growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the whole product vary can be provided year-round, offered to end users throughout Germany via 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 get together brands. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now transformed into integrated, controlled growers of salads and greens and another arm for processing these products. As a household enterprise, Gartenfrisch Jung has been passed from one generation to the following ever since it started. The experience gained as a result has due to this fact grown steadily, resulting in the company’s successful growth and a top quality standard of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw meals daily. This is equal to dealing with 2,000 pallets, that are then delivered to clients by 80 refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the past, these packaging machines were geared up with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These thirteen vacuum pumps were used to evacuate the trays to the required vacuum degree previous to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continually throughout these shifts, other than during breaks. During a third shift, the manufacturing services are cleaned while all machinery is stationary.
Jochen Neff, who is in control of expertise at Gartenfrisch Jung, was in search of another vacuum supply, because the heat radiated by the thirteen vacuum pumps was putting a pressure on the air-con system in the production facilities, that are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum consultants from Busch Vacuum Solutions analyzed the state of affairs and really helpful a centralized vacuum provide, which could be set up in a non-air-conditioned room exterior the production amenities.
Because Jung’s comfort merchandise have the ideal vacuum for packaging at a vacuum degree of 400 millibars, Busch recommended utilizing MINK claw vacuum pumps. This kind of vacuum pump has the very best effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free operating principle, which means that the moving components inside the vacuum pump do not are available 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 eliminated.
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 rating of eight kilowatts. However, one of the three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to guarantee that all three vacuum pumps have the same variety of operating hours.
Centralizing the vacuum supply enabled the entire put in motor score 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. maximum energy. This would correspond to a 68 % reduction in energy consumption. However, in apply Jochen Neff has found that solely one of many two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational pace. After several months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the whole vacuum supply. This is mainly linked to the truth that the twelve packaging strains don’t all always run at maximum speed and not the entire machines are in use all the time. เกวัดแรงดันน้ำ -based control system then decreases the rotational pace to scale back the output, meaning that the system only offers the performance that is really required. In apply, this equates to energy financial savings of over 90 % for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is linked to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every make certain that the required vacuum stage is available within the packaging chambers as soon as it is wanted within the packaging cycle. Removing the thirteen original vacuum pumps from the manufacturing areas relieved strain from the air-con system. This meant that the air con system might be turned down to hold the room temperature between 5 and 6 levels Celsius. The savings in power costs because of reducing the air-con output haven’t been measured. However, it might possibly generally be assumed that the change resulted in a major discount within the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the person MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are practically 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 convenience merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the two vacuum vessels in 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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