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Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit kind a half of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market chief for recent comfort merchandise thanks to its high quality and experience. Since early 2019, the vacuum provide 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 comfort meals in a contemporary facility in Jagsthausen, a town in the German state of Baden-Württemberg. To permit it to produce fresh uncooked produce all 12 months spherical, the company has its personal growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the whole product range can be supplied year-round, bought to end customers across Germany through supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, in addition to for third celebration manufacturers. Gartenfrisch Jung’s historical past dates back to 1795. What began out as a small piece of farmland has now transformed into integrated, controlled growers of salads and greens and another arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one generation to the next ever since it started. The expertise gained consequently has subsequently grown steadily, resulting in the company’s profitable development and a high quality commonplace of its merchandise. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked food every single day. This is equal to dealing with 2,000 pallets, that are then delivered to clients by eighty refrigerated autos.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging traces with tray sealer packaging machines. In the previous, these packaging machines were geared up with one rotary vane vacuum pump each, 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. compound gauge ราคา -shift operation is in place on all twelve packaging lines. The vacuum pumps ran continuously all through these shifts, other than throughout breaks. During a third shift, the manufacturing amenities are cleaned while all machinery is stationary.
Jochen Neff, who is in cost of expertise at Gartenfrisch Jung, was in search of an alternate vacuum provide, as a result of the warmth radiated by the 13 vacuum pumps was putting a pressure 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 experts from Busch Vacuum Solutions analyzed the state of affairs and recommended a centralized vacuum provide, which might be arrange in a non-air-conditioned room exterior the production amenities.
Because Jung’s comfort products have the best 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 very best effectivity issue out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which implies that the shifting components inside the vacuum pump do not come in contact with one another. In turn, no oil-based lubrication is required and all maintenance work related to using 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 equipped with a motor with a nominal motor rating of eight kilowatts. However, one of many three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the same number of operating hours.
Centralizing the vacuum supply enabled the whole installed 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 reduction in power consumption. However, in follow Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a lowered rotational speed. After several months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the complete vacuum supply. This is especially linked to the truth that the twelve packaging traces do not all at all times run at most speed and never all of the machines are in use all the time. The demand-based management system then decreases the rotational pace to scale back the output, meaning that the system only offers the efficiency that is truly required. In apply, this equates to power savings of over 90 % for vacuum generation.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is connected to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a quantity of 1,500 liters every make sure that the required vacuum stage is available within the packaging chambers as soon as it’s wanted within the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved pressure from the air con system. This meant that the air-con system might be turned all the method down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in energy prices as a outcome of lowering the air-con output haven’t been measured. However, it could typically be assumed that the change resulted in a significant reduction in the energy 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 restricted 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, dependable and economical vacuum supply for packaging his comfort merchandise.
Fig: 1: One of twelve strains used to package comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps throughout assembly with the two vacuum vessels within the background
Fig. 3: 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