Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has evolved into the German market chief for fresh comfort merchandise thanks to its quality and expertise. Since early 2019, the vacuum provide 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 modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To enable it to provide recent uncooked produce all yr round, the company has its personal growers in Germany and Portugal. Cultivation in two different climate zones ensures that the whole product vary could be equipped year-round, sold to end users across Germany by way of grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s own label, as properly as for third celebration brands. Gartenfrisch Jung’s history dates back to 1795. What started out as ตัววัดแรงดัน of farmland has now remodeled into integrated, managed growers of salads and greens and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one technology to the following ever since it started. The experience gained consequently has subsequently grown steadily, leading to the company’s successful improvement and a high quality commonplace of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw food every single day. This is equal to handling 2,000 pallets, that are then delivered to customers by eighty refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging strains with tray sealer packaging machines. In the previous, 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 traces. The vacuum pumps ran constantly all through these shifts, other than throughout breaks. During a third shift, the production services are cleaned while all equipment is stationary.
Jochen Neff, who’s in command of technology at Gartenfrisch Jung, was in search of an alternative vacuum supply, as a outcome of the warmth radiated by the 13 vacuum pumps was placing a pressure on the air-con system in the manufacturing amenities, 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 specialists from Busch Vacuum Solutions analyzed the situation and really helpful a centralized vacuum provide, which could be set up in a non-air-conditioned room exterior the production services.
Because Jung’s comfort merchandise have the perfect vacuum for packaging at a vacuum level of four hundred millibars, Busch really helpful using MINK claw vacuum pumps. This type of vacuum pump has the best effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free operating precept, which implies that the moving parts contained in the vacuum pump don’t come in contact with one another. In flip, no oil-based lubrication is required and all maintenance work associated to the use of oil as an operating fluid is eradicated.
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 exclusively on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum supply enabled the total installed motor rating to be lowered 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 p.c discount in power consumption. However, in practice Jochen Neff has discovered 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 average energy consumption of 4 kilowatt hours for the complete vacuum supply. This is mainly linked to the fact that the twelve packaging lines do not all at all times run at maximum velocity and never the entire machines are in use all the time. The demand-based control system then decreases the rotational pace to minimize back the output, meaning that the system solely supplies the performance that’s really required. In follow, this equates to vitality savings of over 90 percent for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is connected to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be sure that the required vacuum level is on the market in the packaging chambers as soon as it is needed within the packaging cycle. Removing the thirteen original vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air-con system could be turned right down to maintain the room temperature between 5 and 6 levels Celsius. The savings in energy prices as a end result of reducing the air-con output have not been measured. However, it might 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, upkeep can be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is restricted 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 highly energy-efficient, dependable and economical vacuum supply for packaging his comfort 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 throughout meeting with the two vacuum vessels in the background
Fig. three: Comparison of energy consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020