Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established company 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 set up 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 allow it to provide fresh raw produce all yr round, the corporate has its personal growers in Germany and Portugal. Cultivation in two completely different local weather zones ensures that the complete product vary can be provided year-round, sold to end customers throughout Germany through supermarket chains and discount stores. The ready-to-eat salads are packaged into bowls underneath the company’s own label, as well as 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 built-in, controlled growers of salads and vegetables and another arm for processing these merchandise. As a family enterprise, Gartenfrisch Jung has been handed from one generation to the following ever since it started. The expertise gained in consequence has due to this fact grown steadily, leading to the company’s successful growth and a high quality standard of its products. Nowadays, Gartenfrisch Jung processes one hundred twenty tonnes of uncooked meals daily. This is equivalent to handling 2,000 pallets, which are then delivered to customers by eighty refrigerated automobiles.
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 have been 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 level prior to sealing. Downloadable -shift operation is in place on all twelve packaging strains. The vacuum pumps ran constantly throughout these shifts, apart from during breaks. During a third shift, the manufacturing services are cleaned while all equipment is stationary.
Jochen Neff, who is in command 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 placing a strain on the air con system in the production services, which 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 recommended a centralized vacuum supply, which might be set up in a non-air-conditioned room outdoors the production facilities.
Because Jung’s convenience products have the best vacuum for packaging at a vacuum level of 400 millibars, Busch recommended utilizing MINK claw vacuum pumps. This kind of vacuum pump has the highest efficiency issue out of all mechanical vacuum pumps. This is a results of their contact-free operating principle, which implies that the shifting parts inside the vacuum pump do not are out there in contact with each other. In turn, no oil-based lubrication is required and all maintenance 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), 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 solely on stand-by. Nevertheless, the management system is programmed to make sure that all three vacuum pumps have the same variety of working hours.
Centralizing the vacuum supply enabled the whole put in motor ranking 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. most power. This would correspond to a 68 p.c reduction in energy consumption. However, in apply Jochen Neff has discovered that solely one of the two MINK claw vacuum pumps is often in use and that this tends to run at a reduced rotational pace. After a number of months of use, Jochen Neff has measured average energy consumption of four kilowatt hours for the whole vacuum provide. This is principally linked to the fact that the twelve packaging lines don’t all at all times run at most pace and never all of the machines are in use all the time. The demand-based management system then decreases the rotational speed to scale back the output, meaning that the system only supplies the efficiency that’s actually required. In apply, this equates to power savings of over ninety % for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use each 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 make sure that the required vacuum degree is available within the packaging chambers as quickly as it’s needed within the packaging cycle. Removing the 13 unique vacuum pumps from the manufacturing areas relieved strain from the air-con system. This meant that the air con system could possibly be turned right down to keep the room temperature between 5 and 6 levels Celsius. The savings in vitality costs as a end result of reducing the air conditioning output haven’t been measured. However, it can usually be assumed that the change resulted in a significant discount in the energy consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, upkeep may be carried out on the person MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are nearly 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 provide for packaging his comfort merchandise.
Fig: 1: One of twelve strains used to bundle 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 power 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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