Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market chief for recent comfort merchandise because of its high quality and expertise. 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 convenience foods in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to produce contemporary raw produce all year round, the company has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the whole product vary can be provided year-round, sold to finish customers across Germany by way of supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s own label, in addition to for third celebration manufacturers. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now reworked into built-in, controlled growers of salads and greens and one other arm for processing these merchandise. As a family enterprise, Gartenfrisch Jung has been passed from one technology to the next ever since it started. The experience gained in consequence has therefore grown steadily, leading to the company’s profitable growth and a excessive quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw meals every single day. This is equivalent to dealing with 2,000 pallets, that 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 previous, these packaging machines were outfitted 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 degree previous to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continually all through these shifts, apart from during breaks. During a 3rd shift, the manufacturing amenities are cleaned whereas all machinery is stationary.
Jochen Neff, who’s in command of expertise at Gartenfrisch Jung, was on the lookout for an alternative vacuum supply, as a result of the warmth radiated by the 13 vacuum pumps was placing a strain on the air con system within the production amenities, 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 situation and beneficial a centralized vacuum supply, which could probably be arrange in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s comfort products have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch recommended using MINK claw vacuum pumps. This type of vacuum pump has the highest efficiency issue out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which signifies that the transferring elements inside the vacuum pump do not are available contact with one another. In turn, no oil-based lubrication is required and all upkeep work associated to the usage of oil as an operating fluid is eradicated.
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 score of eight kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to guarantee that all three vacuum pumps have the identical variety of operating hours.
Centralizing the vacuum supply enabled the whole put in motor rating to be reduced 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 sixty eight p.c reduction in power consumption. However, in apply Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is normally in use and that this tends to run at a reduced rotational velocity. After a number of months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the complete vacuum supply. This is especially linked to the truth that the twelve packaging traces do not all always run at maximum velocity and not the entire 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 supplies the performance that’s really required. In apply, this equates to power financial savings of over ninety percent for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is linked to the packaging machines through a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be sure that the required vacuum degree is out there within the packaging chambers as quickly as it is wanted within the packaging cycle. Removing the thirteen original vacuum pumps from the production areas relieved pressure from the air con system. This meant that the air conditioning system could be turned right down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in power costs on account of decreasing the air-con output haven’t been measured. However, it may possibly usually be assumed that the change resulted in a significant discount within the power consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the individual MINK claw vacuum pumps throughout production and packaging. เกจ์แรงดัน are almost maintenance-free. Maintenance is proscribed mainly 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 extremely energy-efficient, dependable 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. 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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