Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market chief for recent convenience merchandise due to its quality and experience. Since early 2019, the vacuum supply to its tray sealer packaging machines has been exceptionally energy-efficient following the installation of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its comfort meals in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to produce contemporary uncooked produce all year spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the complete product range could be provided year-round, bought to finish customers across Germany through grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls underneath the company’s personal label, in addition to for third get together manufacturers. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now reworked into integrated, controlled growers of salads and greens and one other arm for processing these products. As a household business, Gartenfrisch Jung has been passed from one technology to the subsequent ever because it began. The experience gained as a result has due to this fact grown steadily, leading to the company’s profitable growth and a high quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals every day. This is equivalent to handling 2,000 pallets, which are then delivered to customers by 80 refrigerated autos.
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 equipped with one rotary vane vacuum pump each, though one machine had two vacuum pumps. These 13 vacuum pumps have 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 traces. The vacuum pumps ran continually throughout these shifts, aside from throughout breaks. During a 3rd shift, the manufacturing amenities are cleaned whereas all machinery is stationary.
Jochen Neff, who’s in command of technology at Gartenfrisch Jung, was looking for an alternative vacuum supply, as a end result of the heat radiated by the 13 vacuum pumps was putting a pressure on the air-con system within the production facilities, which are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the state of affairs and beneficial a centralized vacuum supply, which could possibly be set up in a non-air-conditioned room exterior the production amenities.
Because Jung’s comfort products have the best vacuum for packaging at a vacuum stage of four hundred millibars, Busch really helpful using MINK claw vacuum pumps. This sort of vacuum pump has the very best efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free operating precept, which means that the moving parts inside the vacuum pump do not are available in contact with each other. In flip, 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), every of which was geared up with a motor with a nominal motor ranking of 8 kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same variety of operating hours.
Centralizing the vacuum provide enabled the entire installed motor ranking to be decreased from 50.2 to sixteen 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 discount in energy consumption. However, in apply เกจ์วัดแรงดันลม has found that only one of the two MINK claw vacuum pumps is often in use and that this tends to run at a lowered rotational speed. After a number of months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the entire vacuum supply. This is principally linked to the truth that the twelve packaging lines do not all all the time run at most pace and not all the machines are in use on an everyday basis. The demand-based management system then decreases the rotational velocity to cut back the output, that means that the system only provides the performance that is truly required. In apply, this equates to vitality savings of over 90 p.c 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 quantity of 1,500 liters each be certain that the required vacuum stage is out there in the packaging chambers as quickly as it is needed in the packaging cycle. Removing the thirteen authentic vacuum pumps from the production 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 savings in vitality prices as a end result of decreasing the air con output have not been measured. However, it could generally be assumed that the change resulted in a major reduction in the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the person MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are nearly 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 comfort merchandise.
Fig: 1: One of twelve lines used to bundle convenience 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. 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
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