Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. เกจวัดแรงดัน4บาร์ -established company has advanced into the German market leader for recent comfort merchandise due to its quality and expertise. 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 convenience meals in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To allow it to produce fresh raw produce all yr spherical, the company has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the complete product vary could be supplied year-round, sold to end customers across Germany by way of grocery store chains and discount shops. The ready-to-eat salads are packaged into bowls beneath the company’s personal label, as nicely as for third get together manufacturers. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now transformed into built-in, controlled growers of salads and greens and another arm for processing these products. As a household business, Gartenfrisch Jung has been passed from one generation to the subsequent ever since it started. The expertise gained consequently has due to this fact grown steadily, resulting in the company’s profitable development and a high quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food every single day. This is equivalent to handling 2,000 pallets, which are then delivered to customers by eighty refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In the past, these packaging machines were outfitted with one rotary vane vacuum pump each, though one machine had two vacuum pumps. These thirteen vacuum pumps were used to evacuate the trays to the required vacuum degree previous to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continuously all through these shifts, apart from during breaks. During a 3rd shift, the manufacturing amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who is in cost of know-how at Gartenfrisch Jung, was in search of an alternative vacuum supply, as a outcome of the heat radiated by the 13 vacuum pumps was placing a strain on the air conditioning system within the production amenities, that 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 specialists from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum supply, which could possibly be set up in a non-air-conditioned room exterior the manufacturing amenities.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum level of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This sort of vacuum pump has the best efficiency factor out of all mechanical vacuum pumps. This is a result of their contact-free working precept, which means that the transferring elements contained in the vacuum pump do not are out there in contact with each other. In turn, no oil-based lubrication is required and all maintenance work related 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 geared up with a motor with a nominal motor rating of 8 kilowatts. However, one of the three vacuum pumps is completely on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum provide 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. most power. This would correspond to a sixty eight percent discount in energy consumption. However, in apply Jochen Neff has found that solely one of the two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational speed. After a quantity of months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the complete vacuum provide. 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 an everyday basis. The demand-based control system then decreases the rotational velocity to cut back the output, meaning that the system only offers the performance that is actually required. In follow, this equates to power savings of over ninety p.c for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines by way of a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each make sure that the required vacuum level is out there within the packaging chambers as soon as it’s needed in the packaging cycle. Removing the thirteen authentic vacuum pumps from the manufacturing areas relieved strain from the air con system. This meant that the air-con system could possibly be turned right down to keep the room temperature between 5 and 6 levels Celsius. The financial savings in vitality prices on account of decreasing the air conditioning output haven’t been measured. However, it could possibly generally be assumed that the change resulted in a big reduction within the power consumed by the air-con system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the individual MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is proscribed 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, dependable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve traces used to package comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the two vacuum vessels in the background
Fig. three: 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