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 firm has evolved into the German market leader for recent comfort merchandise because of its 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 convenience meals in a modern facility in Jagsthausen, a town within the German state of Baden-Württemberg. To allow it to supply fresh raw produce all 12 months round, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the complete product range can be supplied year-round, bought to finish users across 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 get together manufacturers. Gartenfrisch Jung’s history dates back to 1795. What began out as a small piece of farmland has now remodeled into built-in, controlled growers of salads and vegetables and one other arm for processing these products. As a household business, Gartenfrisch Jung has been handed from one technology to the following ever because it started. The experience gained in consequence has therefore grown steadily, resulting in the company’s profitable growth and a high quality commonplace of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked food every single day. This is equal to dealing with 2,000 pallets, that are then delivered to customers 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 have been outfitted with one rotary vane vacuum pump every, although one machine had two vacuum pumps. เกจวัดไนโตรเจนราคา were used to evacuate the trays to the required vacuum level prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran continuously throughout these shifts, aside from throughout breaks. During a 3rd shift, the production amenities are cleaned whereas 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 end result of the warmth radiated by the thirteen vacuum pumps was putting a pressure on the air conditioning system in the production amenities, that are cooled to between 5 and 6 degrees Celsius. Furthermore, the vacuum pumps had an put in motor output of over 50 kilowatts. The vacuum experts from Busch Vacuum Solutions analyzed the situation and beneficial a centralized vacuum provide, which could probably be arrange in a non-air-conditioned room outside the production facilities.
Because Jung’s convenience products have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch really helpful utilizing MINK claw vacuum pumps. This sort of vacuum pump has the best efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free working precept, which means that the transferring components inside the vacuum pump do not are available 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 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 ranking of 8 kilowatts. However, one of many three vacuum pumps is exclusively on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same number of working hours.
Centralizing the vacuum provide enabled the entire 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 sixty eight percent discount in energy consumption. However, in practice Jochen Neff has discovered that only one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a decreased rotational velocity. After several months of use, Jochen Neff has measured average power consumption of 4 kilowatt hours for the entire vacuum provide. This is especially linked to the truth that the twelve packaging lines do not all always run at maximum velocity and not all of the machines are in use on a daily basis. The demand-based control system then decreases the rotational pace to reduce the output, which means that the system solely provides the performance that’s truly required. In เกจวัดแรงดันไทวัสดุ , this equates to vitality financial 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 connected to the packaging machines through a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters every be sure that the required vacuum level is out there in the packaging chambers as soon as it’s needed in the packaging cycle. Removing the thirteen authentic vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air con system could probably be turned all the means down to hold the room temperature between 5 and 6 degrees Celsius. The financial savings in vitality prices as a end result of lowering the air-con output have not been measured. However, it could possibly usually be assumed that the change resulted in a major 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 individual MINK claw vacuum pumps during manufacturing and packaging. MINK claw vacuum pumps are practically maintenance-free. Maintenance is restricted mainly 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, reliable and economical vacuum supply for packaging his convenience merchandise.
Fig: 1: One of twelve lines 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 energy 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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