Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for contemporary comfort merchandise because of its high 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 within the German state of Baden-Württemberg. To allow it to provide contemporary uncooked produce all year spherical, the corporate has its own growers in Germany and Portugal. Cultivation in two completely different climate zones ensures that the complete product range can be supplied year-round, sold to end users throughout Germany through supermarket chains and low cost stores. The ready-to-eat salads are packaged into bowls beneath the company’s own label, as properly as for third celebration manufacturers. Gartenfrisch Jung’s history dates back to 1795. What started out as a small piece of farmland has now remodeled into built-in, managed growers of salads and vegetables and another arm for processing these products. As a family enterprise, Gartenfrisch Jung has been handed from one generation to the subsequent ever since it began. The expertise gained in consequence has therefore grown steadily, leading to the company’s profitable development and a prime quality normal of its merchandise. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw meals every day. This is equal to handling 2,000 pallets, which are then delivered to customers by 80 refrigerated vehicles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging lines with tray sealer packaging machines. In pressure gauge แบบ น้ำมัน , these packaging machines have been geared up with one rotary vane vacuum pump every, though one machine had two vacuum pumps. เกจวัดแรงดันถังลม had been used to evacuate the trays to the required vacuum degree prior 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 during breaks. During a 3rd shift, the production amenities are cleaned while all equipment is stationary.
Jochen Neff, who’s in control of know-how at Gartenfrisch Jung, was on the lookout for an alternative vacuum supply, because the heat radiated by the thirteen vacuum pumps was putting a strain on the air conditioning system in the production facilities, 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 experts from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum supply, which could possibly be arrange in a non-air-conditioned room outside the production amenities.
Because Jung’s comfort merchandise have the best vacuum for packaging at a vacuum level of four hundred 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 precept, which signifies that the transferring parts inside the vacuum pump do not are obtainable in contact with each other. In flip, no oil-based lubrication is required and all upkeep work related to the use of 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 equipped with a motor with a nominal motor rating of 8 kilowatts. However, one of many three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to guarantee that all three vacuum pumps have the identical variety of working hours.
Centralizing the vacuum supply enabled the total installed motor score to be lowered 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 68 percent reduction in vitality consumption. However, in follow 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 reduced rotational velocity. After several months of use, Jochen Neff has measured common energy consumption of four kilowatt hours for the whole vacuum supply. This is especially linked to the truth that the twelve packaging traces don’t all always run at most pace and never the entire machines are in use on a regular basis. The demand-based management system then decreases the rotational speed to cut back the output, which means that the system solely offers the efficiency that is really required. In follow, this equates to power savings of over ninety p.c for vacuum technology.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is linked to the packaging machines through a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be sure that the required vacuum level is available within the packaging chambers as soon as it’s needed in the packaging cycle. Removing the 13 authentic vacuum pumps from the production areas relieved pressure from the air-con system. This meant that the air con system could be turned all the means down to keep the room temperature between 5 and 6 levels Celsius. The savings in power prices on account of decreasing the air-con output have not been measured. However, it can typically be assumed that the change resulted in a significant discount in the energy consumed by the air con system.
Thanks to the vacuum system’s redundant design, maintenance can be carried out on the person MINK claw vacuum pumps during manufacturing 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 highly energy-efficient, reliable and economical vacuum supply 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 during assembly with the 2 vacuum vessels in the background
Fig. 3: Comparison of vitality consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020