Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for contemporary convenience products due to 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.
Gartenfrisch Jung produces its comfort meals in a contemporary facility in Jagsthausen, a city within the German state of Baden-Württemberg. To enable it to supply recent raw produce all 12 months spherical, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the entire product vary can be provided year-round, offered to finish users across Germany through supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls beneath the company’s personal label, in addition to for third celebration brands. Gartenfrisch Jung’s historical past dates again to 1795. What started out as a small piece of farmland has now reworked into built-in, managed growers of salads and greens and another arm for processing these merchandise. As a household business, Gartenfrisch Jung has been handed from one era to the next ever since it began. เกจ์วัดแรงดันแก๊ส gained as a result has therefore grown steadily, leading to the company’s successful development and a excessive quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals daily. This is equal to dealing with 2,000 pallets, that are then delivered to customers by 80 refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging strains with tray sealer packaging machines. In the past, these packaging machines had been geared up 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 lines. The vacuum pumps ran continually throughout these shifts, aside from during breaks. During a third shift, the production amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in command of expertise at Gartenfrisch Jung, was looking for an alternative vacuum supply, as a outcome of the heat radiated by the 13 vacuum pumps was putting a pressure on the air-con system within the production facilities, that 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 consultants from Busch Vacuum Solutions analyzed the scenario and beneficial a centralized vacuum provide, which might be arrange in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum level of 400 millibars, Busch recommended using MINK claw vacuum pumps. This kind of vacuum pump has the highest effectivity factor out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which implies that the shifting elements contained in the vacuum pump do not are available in contact with each other. In flip, no oil-based lubrication is required and all upkeep work associated to using 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 geared up with a motor with a nominal motor score of 8 kilowatts. However, one of the three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum provide enabled the whole put in 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. most power. This would correspond to a 68 percent discount in energy consumption. However, in apply Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a reduced 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 mainly linked to the reality that the twelve packaging strains do not all always run at most pace and never the entire machines are in use on a daily basis. The demand-based management system then decreases the rotational speed to reduce the output, which means that the system only offers the performance that is really required. In follow, this equates to vitality savings of over 90 percent for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is related to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be certain that the required vacuum level is out there within the packaging chambers as soon as it’s wanted within the packaging cycle. Removing the 13 unique vacuum pumps from the production areas relieved pressure from the air con system. This meant that the air-con system could possibly be turned down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in energy costs on account of decreasing the air conditioning output haven’t been measured. However, it may possibly typically be assumed that the change resulted in a significant discount within the power 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 throughout production and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is limited 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 provide for packaging his convenience products.
Fig: 1: One of twelve traces used to bundle comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the 2 vacuum vessels in the background
Fig. 3: Comparison of vitality 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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