Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market chief for fresh comfort merchandise thanks to its quality and experience. 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 comfort meals in a modern facility in Jagsthausen, a city in the German state of Baden-Württemberg. To allow it to provide fresh raw produce all 12 months round, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the complete product range could be supplied year-round, offered to finish customers throughout Germany via supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, as nicely as for third party manufacturers. เกจวัดแรงดันต่ำ to 1795. What started out as a small piece of farmland has now remodeled into built-in, managed growers of salads and vegetables and one other arm for processing these products. As a household enterprise, Gartenfrisch Jung has been passed from one generation to the following ever because it started. The experience gained as a result has subsequently grown steadily, leading to the company’s successful improvement and a excessive quality standard of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of raw food daily. This is equal to handling 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 lines with tray sealer packaging machines. In the previous, these packaging machines had been outfitted with one rotary vane vacuum pump every, though 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 strains. The vacuum pumps ran continuously throughout these shifts, aside from during breaks. During a third shift, the manufacturing services are cleaned whereas all machinery is stationary.
Jochen Neff, who’s in cost of expertise at Gartenfrisch Jung, was on the lookout for an alternate vacuum provide, as a outcome of the heat radiated by the thirteen vacuum pumps was putting a strain on the air-con system within the production facilities, which are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum consultants from Busch Vacuum Solutions analyzed the state of affairs and beneficial a centralized vacuum provide, which might be set up in a non-air-conditioned room exterior the manufacturing facilities.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum level of four hundred millibars, Busch recommended using MINK claw vacuum pumps. This kind of vacuum pump has the highest efficiency issue out of all mechanical vacuum pumps. This is a result of their contact-free operating principle, which implies that the shifting components inside the vacuum pump don’t are available contact with each other. In flip, no oil-based lubrication is required and all maintenance work related 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), each of which was equipped 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 guarantee that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum supply enabled the entire put in motor score 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 energy. This would correspond to a sixty eight percent reduction in energy consumption. However, in practice Jochen Neff has discovered that solely one of many two MINK claw vacuum pumps is often in use and that this tends to run at a lowered rotational pace. After a quantity of months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum supply. This is mainly linked to the reality that the twelve packaging strains don’t all always run at maximum pace and not the entire machines are in use all the time. The demand-based control system then decreases the rotational pace to scale back the output, meaning that the system only supplies the efficiency that’s truly required. In practice, this equates to energy financial savings of over 90 percent for vacuum era.
The new centralized vacuum system was installed 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 quantity of 1,500 liters each ensure that the required vacuum level is on the market within the packaging chambers as soon as it is wanted in the packaging cycle. Removing the thirteen unique 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 financial savings in vitality costs on account of reducing the air conditioning output have not been measured. However, it might possibly generally be assumed that the change resulted in a significant reduction in the energy consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the individual MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are almost maintenance-free. Maintenance is limited primarily 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, reliable and economical vacuum provide for packaging his comfort products.
Fig: 1: One of twelve strains used to package deal convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the 2 vacuum vessels in the background
Fig. 3: 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