Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly cut fruit type part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has developed into the German market leader for contemporary comfort products 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 set up of a central vacuum system by Busch Vacuum Solutions.
Gartenfrisch Jung produces its convenience meals in a contemporary facility in Jagsthausen, a city within the German state of Baden-Württemberg. To allow it to provide fresh uncooked produce all yr round, the corporate has its own growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the whole product range could be provided year-round, sold to end users across Germany via supermarket chains and discount shops. The ready-to-eat salads are packaged into bowls under the company’s personal label, as nicely as for third party brands. Gartenfrisch Jung’s history dates back to 1795. What began out as a small piece of farmland has now transformed into built-in, controlled growers of salads and greens and another arm for processing these products. As a household enterprise, Gartenfrisch Jung has been passed from one generation to the subsequent ever because it started. The experience gained consequently has therefore grown steadily, resulting in the company’s successful development and a prime quality normal of its products. Nowadays, Gartenfrisch Jung processes a hundred and twenty tonnes of uncooked food every single day. This is equivalent to handling 2,000 pallets, which are then delivered to customers by 80 refrigerated automobiles.
The ready-to-eat salad dishes (Fig. 1) are packaged on twelve packaging strains with tray sealer packaging machines. In the previous, these packaging machines were equipped with one rotary vane vacuum pump each, although one machine had two vacuum pumps. These 13 vacuum pumps had been used to evacuate the trays to the required vacuum stage prior to sealing. A two-shift operation is in place on all twelve packaging traces. The vacuum pumps ran continually throughout these shifts, other than throughout breaks. During a 3rd shift, the production facilities are cleaned whereas all machinery is stationary.
Jochen Neff, who is in cost of expertise at Gartenfrisch Jung, was on the lookout for an alternate vacuum provide, as a result of the heat radiated by the 13 vacuum pumps was putting a strain on the air-con system within the production services, that are cooled to between 5 and 6 degrees 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 beneficial a centralized vacuum provide, which could be arrange in a non-air-conditioned room outdoors the manufacturing services.
Because Jung’s convenience products have the perfect vacuum for packaging at a vacuum level of 400 millibars, Busch beneficial utilizing MINK claw vacuum pumps. This type of vacuum pump has the very best effectivity factor out of all mechanical vacuum pumps. This is a result of their contact-free working precept, which means that the shifting parts inside the vacuum pump don’t come in contact with each other. In turn, no oil-based lubrication is required and all upkeep work related to using oil as an operating fluid is eliminated.
Busch designed a vacuum system with three frequency-controlled MINK claw vacuum pumps (Fig. 2), every of which was outfitted with a motor with a nominal motor ranking 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 identical number of working hours.
Centralizing the vacuum provide enabled the entire put in motor ranking to be reduced 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 p.c discount in energy consumption. However, in practice 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 decreased rotational speed. After a number of months of use, Jochen Neff has measured common power consumption of 4 kilowatt hours for the complete vacuum supply. This is principally linked to the reality that the twelve packaging traces don’t all always run at most velocity and not all of the machines are in use all the time. The demand-based management system then decreases the rotational velocity to cut back the output, that means that the system only supplies the performance that is truly required. In apply, this equates to vitality savings of over 90 p.c for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use each since. Invitation only is connected to the packaging machines via a network of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each be positive that the required vacuum level is on the market 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 strain from the air conditioning system. This meant that the air conditioning system could possibly be turned down to keep the room temperature between 5 and 6 degrees Celsius. The savings in vitality prices because of lowering the air-con output haven’t been measured. However, it could typically be assumed that the change resulted in a big reduction in the vitality consumed by the air con system.
Thanks to the vacuum system’s redundant design, upkeep can be carried out on the person MINK claw vacuum pumps throughout production and packaging. MINK claw vacuum pumps are practically 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, reliable and economical vacuum provide for packaging his convenience merchandise.
Fig: 1: One of twelve strains used to package convenience merchandise on tray sealers
Fig. 2: Vacuum system with three MINK claw vacuum pumps during assembly with the 2 vacuum vessels in the background
Fig. three: 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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