Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market leader for recent convenience merchandise because of its high quality and expertise. 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 foods in a modern facility in Jagsthausen, a city in the German state of Baden-Württemberg. To enable it to provide fresh raw produce all yr spherical, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different climate zones ensures that the whole product vary could be provided year-round, offered to end users across Germany through grocery store chains and discount shops. 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 history dates back to 1795. What began out as a small piece of farmland has now transformed into built-in, controlled growers of salads and greens and another arm for processing these products. As a family enterprise, Gartenfrisch Jung has been handed from one era to the following ever since it started. The experience gained as a result has due to this fact grown steadily, leading to the company’s profitable development and a top quality commonplace of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked meals every single day. This is equal to dealing with 2,000 pallets, that are then delivered to clients by 80 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 were geared up with one rotary vane vacuum pump every, although one machine had two vacuum pumps. These 13 vacuum pumps were used to evacuate the trays to the required vacuum degree prior to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continuously all through these shifts, aside from during breaks. During a 3rd shift, the production amenities are cleaned while all equipment is stationary.
Jochen Neff, who’s in control of expertise at Gartenfrisch Jung, was in search of another vacuum supply, as a end result of the warmth radiated by the thirteen vacuum pumps was placing a pressure on the air conditioning system in the manufacturing amenities, which are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an installed motor output of over 50 kilowatts. The vacuum specialists from Busch Vacuum Solutions analyzed the scenario and beneficial a centralized vacuum supply, which could possibly be arrange in a non-air-conditioned room outside the manufacturing facilities.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum stage of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This type of vacuum pump has the very best efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free working principle, which signifies that the transferring parts inside the vacuum pump do not are out there in contact with one another. In flip, no oil-based lubrication is required and all upkeep work related to the use 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 score of eight kilowatts. However, one of many three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to ensure that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum supply enabled the whole 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. most power. This would correspond to a 68 % reduction in power consumption. However, in apply Jochen Neff has found that solely one of many 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 power consumption of four kilowatt hours for the entire vacuum supply. This is especially linked to the fact that the twelve packaging strains don’t all always run at most velocity and never the entire machines are in use on an everyday basis. The demand-based management system then decreases the rotational speed to cut back the output, which means that the system solely offers the performance that is truly required. In practice, this equates to energy 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 related to the packaging machines through a community of pipelines. pressure gauge nuova fima ราคา with a quantity of 1,500 liters every make certain that the required vacuum level is out there within the packaging chambers as soon as it is needed in the packaging cycle. Removing the thirteen unique vacuum pumps from the production areas relieved strain from the air-con system. This meant that the air con system could possibly be turned down to maintain the room temperature between 5 and 6 levels Celsius. The savings in vitality costs because of reducing the air conditioning output haven’t been measured. However, it could typically be assumed that the change resulted in a major discount within the power consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep could be carried out on the individual MINK claw vacuum pumps during production and packaging. MINK claw vacuum pumps are almost 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 extremely energy-efficient, dependable and economical vacuum supply for packaging his convenience products.
Fig: 1: One of twelve traces used to package comfort 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. three: Comparison of energy consumption for a decentralized and centralized vacuum provide
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020