Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly reduce fruit kind part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for recent convenience products thanks to 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 in the German state of Baden-Württemberg. To allow it to produce fresh raw produce all 12 months round, the company has its personal growers in Germany and Portugal. Cultivation in two different local weather zones ensures that the whole product range could be equipped year-round, bought to finish users throughout Germany through supermarket chains and low cost shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, as well as for third celebration brands. Gartenfrisch Jung’s historical past dates back to 1795. What started out as a small piece of farmland has now transformed into integrated, controlled growers of salads and vegetables and one other arm for processing these merchandise. As a family business, Gartenfrisch Jung has been passed from one generation to the following ever because it began. The experience gained as a result has subsequently grown steadily, resulting in the company’s successful growth and a excessive quality standard of its merchandise. Nowadays, Gartenfrisch Jung processes 120 tonnes of uncooked meals daily. This is equal to dealing with 2,000 pallets, which are then delivered to clients by eighty refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging strains with tray sealer packaging machines. In the past, these packaging machines were geared up with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These thirteen vacuum pumps were used to evacuate the trays to the required vacuum stage prior to sealing. A two-shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly throughout these shifts, other than during breaks. During a 3rd shift, the manufacturing amenities are cleaned whereas all equipment is stationary.
Jochen Neff, who’s in command of expertise at Gartenfrisch Jung, was in search of an alternate vacuum supply, as a outcome of the warmth radiated by the 13 vacuum pumps was putting a pressure on the air conditioning system within the manufacturing services, 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 really helpful a centralized vacuum supply, which could probably be set up in a non-air-conditioned room outdoors the production services.
Because Jung’s comfort products have the ideal vacuum for packaging at a vacuum degree of 400 millibars, Busch really helpful using MINK claw vacuum pumps. This sort of vacuum pump has the highest efficiency factor out of all mechanical vacuum pumps. This is a results of their contact-free operating principle, which signifies that the moving elements inside the vacuum pump do not are out there 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), each of which was geared up with a motor with a nominal motor score of eight kilowatts. However, one of the three vacuum pumps is exclusively on stand-by. Nevertheless, the control system is programmed to make certain that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum supply enabled the whole installed motor rating to be lowered from 50.2 to 16 kilowatts (Fig. 3) if we assume that two of the vacuum pumps run at 60 Hertz, i.e. maximum energy. This would correspond to a sixty eight p.c reduction in power consumption. However, in follow Jochen Neff has found that only one of the two MINK claw vacuum pumps is normally in use and that this tends to run at a lowered rotational velocity. After several months of use, Jochen Neff has measured common power consumption of four kilowatt hours for the whole vacuum supply. This is especially linked to the reality that the twelve packaging lines don’t all all the time run at maximum velocity and never all of the machines are in use on a regular basis. ที่วัดแรงดัน -based control system then decreases the rotational velocity to scale back the output, which means that the system only supplies the efficiency that is really required. In practice, this equates to power financial savings of over 90 percent for vacuum era.
The new centralized vacuum system was installed in April 2019 and has been in use every since. It is connected to the packaging machines by way of a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each make positive that the required vacuum level is available in the packaging chambers as soon as it is needed in the packaging cycle. Removing the thirteen unique vacuum pumps from the manufacturing areas relieved pressure from the air conditioning system. This meant that the air-con system could be turned all the means down to keep the room temperature between 5 and 6 degrees Celsius. The savings in vitality costs as a end result of reducing the air-con output haven’t been measured. However, it can 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, maintenance could 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 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, reliable and economical vacuum provide for packaging his convenience merchandise.
จำหน่ายเกจวัดแรงดัน : 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 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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