Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market chief for contemporary comfort merchandise due to its quality and experience. Since early 2019, the vacuum supply 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 convenience meals in a modern facility in Jagsthausen, a town in the German state of Baden-Württemberg. To permit it to supply contemporary uncooked produce all 12 months round, the company has its own growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the entire product vary could be supplied year-round, sold to end customers throughout Germany via supermarket chains and discount stores. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third celebration brands. Gartenfrisch Jung’s historical past dates again to 1795. What began out as a small piece of farmland has now remodeled into integrated, controlled growers of salads and greens and one other arm for processing these products. As เกจวัดแรงดันน้ำประปา , Gartenfrisch Jung has been handed from one era to the subsequent ever because it began. The experience gained as a result has therefore grown steadily, leading to the company’s profitable development and a excessive quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw food daily. This is equivalent to handling 2,000 pallets, that are then delivered to customers by 80 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 have been equipped with one rotary vane vacuum pump every, although 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 strains. The vacuum pumps ran constantly all through these shifts, other than throughout breaks. During a 3rd shift, the production facilities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in charge of technology at Gartenfrisch Jung, was on the lookout for another vacuum provide, as a result of the heat radiated by the 13 vacuum pumps was placing a strain on the air conditioning system within the production services, 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 experts from Busch Vacuum Solutions analyzed the state of affairs and recommended a centralized vacuum provide, which could possibly be arrange in a non-air-conditioned room outdoors the production services.
Because Jung’s comfort merchandise have the perfect vacuum for packaging at a vacuum degree of 400 millibars, Busch really helpful using 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 operating principle, which signifies that the transferring parts contained in the vacuum pump do not are available in contact with each other. In turn, no oil-based lubrication is required and all upkeep work related to the usage of oil as an working fluid is eliminated.
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 many three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum provide enabled the whole put in motor ranking 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 energy. This would correspond to a 68 p.c discount in vitality consumption. However, in pressure gauge วัด แรง ดัน has found that solely one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a decreased rotational pace. After several months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the complete vacuum supply. This is especially linked to the reality that the twelve packaging traces don’t all all the time run at maximum velocity and never all of the machines are in use on an everyday basis. The demand-based control system then decreases the rotational pace to reduce the output, which means that the system only provides the performance that’s really required. In practice, this equates to vitality savings of over 90 p.c for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use each since. It is linked to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every ensure that the required vacuum level is on the market in the packaging chambers as quickly as it is needed within the packaging cycle. Removing the thirteen unique vacuum pumps from the production areas relieved pressure from the air con system. This meant that the air-con system might be turned all the method down to maintain the room temperature between 5 and 6 degrees Celsius. The financial savings in vitality prices because of reducing the air con output have not been measured. However, it could generally be assumed that the change resulted in a big discount within the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance may be carried out on the individual MINK claw vacuum pumps during production 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 highly energy-efficient, dependable and economical vacuum provide for packaging his convenience products.
Fig: 1: One of twelve traces used to bundle convenience products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two 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