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 recent 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 set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its comfort meals in a contemporary facility in Jagsthausen, a city in the German state of Baden-Württemberg. To permit it to provide fresh raw produce all yr spherical, the company has its personal growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the entire product range can be provided year-round, sold to end users across Germany through grocery store chains and low cost stores. The ready-to-eat salads are packaged into bowls under the company’s own label, in addition to for third get together manufacturers. Gartenfrisch Jung’s history dates back to 1795. What started out as เกจวัดแรงดัน4นิ้วราคา of farmland has now transformed into built-in, controlled growers of salads and greens and one other arm for processing these merchandise. As a household enterprise, Gartenfrisch Jung has been handed from one era to the subsequent ever since it began. The experience gained consequently has due to this fact grown steadily, resulting in the company’s successful development and a high quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals every single day. This is equivalent to dealing with 2,000 pallets, which are then delivered to prospects by 80 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 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 level previous to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly all through these shifts, aside from during breaks. During a third shift, the production amenities are cleaned while all equipment is stationary.
Jochen Neff, who’s in charge of technology at Gartenfrisch Jung, was in search of an alternative vacuum supply, as a result of the heat radiated by the thirteen vacuum pumps was placing a pressure on the air conditioning system in the manufacturing facilities, that 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 situation and recommended a centralized vacuum provide, which could presumably be arrange in a non-air-conditioned room outside the production facilities.
Because Jung’s comfort merchandise have the ideal vacuum for packaging at a vacuum degree of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This kind of vacuum pump has the very best efficiency issue out of all mechanical vacuum pumps. This is a result of their contact-free working precept, which means that the moving elements inside the vacuum pump don’t are obtainable in contact with each other. In turn, no oil-based lubrication is required and all upkeep work related to using oil as an working 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 many three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the identical number of working hours.
Centralizing the vacuum provide enabled the whole put in motor score to be decreased from 50.2 to sixteen 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 68 p.c discount in energy consumption. However, in follow 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 quantity of months of use, Jochen Neff has measured average power consumption of four kilowatt hours for the complete vacuum supply. This is principally linked to the truth that the twelve packaging lines do not all at all times run at maximum velocity and not the entire machines are in use all the time. The demand-based management system then decreases the rotational speed to scale back the output, meaning that the system only offers the performance that’s really required. In follow, this equates to power financial savings of over ninety p.c for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is connected to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters each ensure that the required vacuum stage is on the market in the packaging chambers as soon as it’s needed within the packaging cycle. Removing the 13 original vacuum pumps from the production areas relieved pressure from the air con system. This meant that the air-con system could probably be turned all the way down to maintain the room temperature between 5 and 6 levels Celsius. The savings in vitality prices as a outcome of lowering the air con output have not 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 person MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are practically 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 provide for packaging his comfort products.
Fig: 1: One of twelve lines used to bundle comfort products on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout meeting with the two vacuum vessels in 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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