Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market chief for fresh comfort products 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 installation of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its comfort meals in a contemporary facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to supply fresh uncooked produce all year round, the corporate has its own growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the entire product vary can be provided year-round, sold to finish users throughout Germany via grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls under the company’s own label, as properly as for third celebration manufacturers. Gartenfrisch Jung’s historical past dates again to 1795. What began out as a small piece of farmland has now transformed into built-in, managed growers of salads and greens and one other arm for processing these merchandise. As a family enterprise, Gartenfrisch Jung has been handed from one era to the following ever because it started. The expertise gained consequently has therefore grown steadily, resulting in the company’s successful improvement and a high quality normal of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked meals every single day. This is equivalent to dealing with 2,000 pallets, that are then delivered to clients by eighty refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the past, these packaging machines had been outfitted with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps were used to evacuate the trays to the required vacuum level prior to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continuously throughout these shifts, other than during breaks. During a third shift, the manufacturing amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in control of technology at Gartenfrisch Jung, was looking for an alternate vacuum supply, as a end result of the warmth radiated by the 13 vacuum pumps was placing a pressure on the air-con system in the production services, 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 experts from Busch Vacuum Solutions analyzed the state of affairs and really helpful a centralized vacuum provide, which could probably be set up in a non-air-conditioned room outdoors the production facilities.
Because Jung’s comfort merchandise have the ideal vacuum for packaging at a vacuum degree of four hundred millibars, Busch recommended utilizing MINK claw vacuum pumps. This type of vacuum pump has the highest effectivity issue out of all mechanical vacuum pumps. This is a result of their contact-free working precept, which means that the transferring parts contained in the vacuum pump do not are out there in contact with one another. In flip, no oil-based lubrication is required and all maintenance work associated to using oil as an working fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), each of which was equipped 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 guarantee that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum provide enabled the total put in 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 energy. This would correspond to a sixty eight percent reduction in energy 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 reduced rotational velocity. After a number of months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the entire vacuum supply. This is especially linked to the reality that the twelve packaging traces do not all always run at most velocity and never all the machines are in use all the time. The demand-based management system then decreases the rotational pace to scale back the output, which means that the system solely offers the performance that’s actually required. In apply, this equates to power financial savings of over 90 % for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each ensure that the required vacuum level is out there in the packaging chambers as soon as it is needed within the packaging cycle. Removing the thirteen original vacuum pumps from the production areas relieved strain from the air-con system. This meant that the air-con system could presumably be turned right down to hold the room temperature between 5 and 6 degrees Celsius. The savings in power costs on account of decreasing the air-con output haven’t been measured. However, it can typically be assumed that the change resulted in a major discount within the vitality consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep may be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. Massive are nearly maintenance-free. Maintenance is proscribed mainly to the annual preventive change in gear oil. First 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 comfort merchandise.
Fig: 1: One of twelve strains used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during meeting with the two vacuum vessels within the background
Fig. three: Comparison of power 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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