Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form a part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company has developed into the German market leader for recent convenience merchandise due 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 foods in a modern facility in Jagsthausen, a city in the German state of Baden-Württemberg. To enable it to supply contemporary raw produce all yr round, the company has its personal growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the whole product range may be equipped year-round, sold to finish 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, as properly as for third get together 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 enterprise, Gartenfrisch Jung has been passed from one generation to the subsequent ever because it started. Surge gained in consequence has therefore grown steadily, leading to the company’s successful improvement and a high quality normal of its products. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of raw meals every single day. This is equivalent to dealing with 2,000 pallets, which are then delivered to prospects by eighty refrigerated vehicles.
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 had been geared up with one rotary vane vacuum pump every, though one machine had two vacuum pumps. These thirteen vacuum pumps had been used to evacuate the trays to the required vacuum level prior to sealing. A two-shift operation is in place on all twelve packaging lines. The vacuum pumps ran continuously throughout these shifts, aside from throughout breaks. During a third shift, the production amenities are cleaned while all equipment is stationary.
Jochen Neff, who’s in charge of know-how at Gartenfrisch Jung, was in search of another vacuum supply, as a outcome of the warmth radiated by the 13 vacuum pumps was putting a strain on the air-con system within the production amenities, that are cooled to between 5 and 6 levels Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the state of affairs and recommended a centralized vacuum supply, which could be arrange in a non-air-conditioned room outdoors the production amenities.
Because Jung’s convenience merchandise have the best vacuum for packaging at a vacuum stage of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This sort of vacuum pump has the best effectivity factor out of all mechanical vacuum pumps. This is a result of their contact-free working principle, which means that the transferring components contained in the vacuum pump do not are obtainable in contact with one another. In flip, no oil-based lubrication is required and all maintenance work associated to using oil as an operating fluid is eradicated.
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 rating of eight kilowatts. However, one of the three vacuum pumps is completely on stand-by. Nevertheless, the control system is programmed to ensure that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum supply enabled the entire put in motor rating 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 % discount in power consumption. However, in apply Jochen Neff has found that solely one of many two MINK claw vacuum pumps is generally in use and that this tends to run at a reduced rotational speed. After several months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the complete vacuum provide. This is especially linked to the reality that the twelve packaging lines don’t all at all times run at most pace and never all the machines are in use all the time. The demand-based management system then decreases the rotational velocity to reduce back the output, meaning that the system only provides the performance that’s really required. In practice, this equates to vitality savings of over ninety % for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use each since. It is related to the packaging machines by way of a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each ensure that the required vacuum stage is out there within the packaging chambers as quickly as it’s 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 be turned all the way down to hold the room temperature between 5 and 6 degrees Celsius. The savings in power prices as a end result of lowering the air con output haven’t been measured. However, it could possibly typically be assumed that the change resulted in a major reduction within the vitality consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep may be carried out on the individual MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are nearly maintenance-free. Maintenance is limited 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 highly energy-efficient, dependable and economical vacuum supply for packaging his convenience merchandise.
Fig: 1: One of twelve strains used to package deal comfort merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the two vacuum vessels in the background
Fig. 3: Comparison of power consumption for a decentralized and centralized vacuum supply
Image rights: Busch Vacuum Solutions
Busch Vacuum Solutions
Global Marketing – Uli Merkle
10 March 2020
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