Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit type a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market leader for fresh convenience products because of 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 foods in a contemporary facility in Jagsthausen, a city within the German state of Baden-Württemberg. To allow it to provide contemporary raw produce all 12 months spherical, the company has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the entire product vary could be supplied year-round, bought to finish users across Germany via grocery store chains and low cost stores. ความหมายของเครื่องวัดความดัน -to-eat salads are packaged into bowls beneath the company’s own label, as well as for third party 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 one other arm for processing these merchandise. As a family enterprise, Gartenfrisch Jung has been handed from one era to the next ever since it started. The experience gained consequently has subsequently grown steadily, resulting in the company’s profitable development and a excessive quality normal of its products. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals every single day. This is equivalent to dealing with 2,000 pallets, that are then delivered to customers by eighty refrigerated automobiles.
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 outfitted with one rotary vane vacuum pump each, though one machine had two vacuum pumps. These thirteen vacuum pumps have been used to evacuate the trays to the required vacuum stage prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continuously throughout these shifts, other than during breaks. During a third shift, the manufacturing facilities are cleaned whereas all machinery is stationary.
Jochen Neff, who is in cost of expertise at Gartenfrisch Jung, was in search of an alternative vacuum provide, as a outcome of the warmth radiated by the 13 vacuum pumps was putting a pressure on the air-con system in the production facilities, which 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 situation and recommended a centralized vacuum provide, which could be arrange in a non-air-conditioned room exterior the production services.
Because Jung’s comfort products have the ideal vacuum for packaging at a vacuum stage of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This type of vacuum pump has the best effectivity factor out of all mechanical vacuum pumps. This is a result of their contact-free operating principle, which implies that the moving parts inside the vacuum pump do not are out there in contact with each other. 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 rating of eight kilowatts. However, one of many three vacuum pumps is solely on stand-by. Nevertheless, the management system is programmed to make certain that all three vacuum pumps have the identical number of operating hours.
Centralizing the vacuum supply enabled the total installed motor rating to be reduced 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 sixty eight percent reduction in power consumption. However, in practice Jochen Neff has discovered that only one of many two MINK claw vacuum pumps is often in use and that this tends to run at a decreased rotational pace. After a number of months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the entire vacuum provide. This is especially linked to the reality that the twelve packaging traces don’t all all the time run at most velocity and not all of the machines are in use on a daily basis. The demand-based management system then decreases the rotational velocity to minimize back the output, which means that the system only offers the performance that’s really required. In follow, this equates to vitality financial savings of over ninety p.c for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is related to the packaging machines through a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be positive that the required vacuum degree is available in the packaging chambers as soon as it is wanted within the packaging cycle. Removing the 13 original vacuum pumps from the production areas relieved strain from the air con system. This meant that the air-con system might be turned down to hold the room temperature between 5 and 6 degrees Celsius. The savings in power prices on account of reducing the air-con output haven’t been measured. However, it could usually be assumed that the change resulted in a big reduction in 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 production and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is limited primarily 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 highly energy-efficient, reliable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve strains used to package convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly 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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