Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market chief for fresh convenience products thanks to 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 comfort meals in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To allow it to supply fresh raw produce all 12 months round, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the whole product range can be provided year-round, bought to finish customers throughout Germany through grocery store chains and low cost stores. เกจอาร์กอน -to-eat salads are packaged into bowls under the company’s own label, in addition to for third celebration manufacturers. Gartenfrisch Jung’s historical past dates back to 1795. What started out as a small piece of farmland has now transformed into built-in, controlled growers of salads and vegetables and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one era to the subsequent ever since it started. The experience gained as a result has therefore grown steadily, leading to the company’s successful development and a high quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw food every day. This is equivalent to dealing with 2,000 pallets, that are then delivered to prospects by 80 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 equipped with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These thirteen vacuum pumps have been used to evacuate the trays to the required vacuum level previous to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran constantly all through these shifts, other than throughout breaks. During a third shift, the production services are cleaned whereas all equipment is stationary.
Jochen Neff, who is in management of expertise at Gartenfrisch Jung, was in search of another vacuum provide, because the warmth radiated by the thirteen vacuum pumps was putting a pressure on the air-con system in the manufacturing amenities, which 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 situation and really helpful a centralized vacuum supply, which could presumably be arrange in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s comfort products have the perfect vacuum for packaging at a vacuum degree of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This kind of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which implies that the transferring components contained in the vacuum pump don’t are available contact with one another. In turn, no oil-based lubrication is required and all upkeep work related 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), each of which was outfitted 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 control system is programmed to ensure that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum supply enabled the total installed motor ranking to be decreased from 50.2 to 16 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 % discount in energy consumption. However, in practice 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 reduced rotational pace. After several months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum supply. This is mainly linked to the fact that the twelve packaging lines don’t all all the time run at most speed and not all the machines are in use all the time. The demand-based management system then decreases the rotational velocity to scale back the output, which means that the system only offers the efficiency that’s actually required. In practice, this equates to vitality savings of over ninety percent for vacuum technology.
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 through a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every be positive that the required vacuum level is out there in the packaging chambers as soon as it’s needed within the packaging cycle. Removing the thirteen unique vacuum pumps from the manufacturing areas relieved strain from the air conditioning system. This meant that the air conditioning system could be turned all the method down to hold the room temperature between 5 and 6 levels Celsius. The savings in vitality prices as a result of reducing the air con output have not been measured. However, it could typically be assumed that the change resulted in a significant discount in the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the person MINK claw vacuum pumps during 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 carried out by a Busch service technician. With the 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 package deal comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the 2 vacuum vessels in the background
Fig. 3: Comparison of energy consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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