Enormous Energy Savings for Packaging Process

Fresh and ready-to-eat salads, vegetable dishes, herbs, and freshly minimize fruit form part of Gartenfrisch Jung GmbH’s product portfolio. The long-established firm has advanced into the German market leader for recent convenience merchandise thanks to 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 meals in a contemporary facility in Jagsthausen, a town in the German state of Baden-Württemberg. To permit it to supply recent uncooked produce all year round, the corporate has its personal growers in Germany and Portugal. Cultivation in two totally different local weather zones ensures that the entire product range may be provided year-round, offered to finish users across Germany by way of supermarket chains and discount stores. The ready-to-eat salads are packaged into bowls under the company’s personal label, as well as for third party manufacturers. Gartenfrisch Jung’s history dates again to 1795. What began out as a small piece of farmland has now transformed into built-in, controlled growers of salads and vegetables and one other arm for processing these merchandise. As a family business, Gartenfrisch Jung has been handed from one technology to the following ever because it began. The expertise gained in consequence has due to this fact grown steadily, resulting in the company’s successful improvement and a high quality standard of its products. Nowadays, Gartenfrisch Jung processes 120 tonnes of raw food every day. This is equal to handling 2,000 pallets, which are then delivered to customers by eighty refrigerated vehicles.
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 outfitted with one rotary vane vacuum pump each, though one machine had two vacuum pumps. These 13 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 traces. The vacuum pumps ran continually all through these shifts, apart from during breaks. During a third shift, the production amenities are cleaned while all machinery is stationary.
Jochen Neff, who is in command of expertise at Gartenfrisch Jung, was on the lookout for an alternate vacuum supply, because the warmth radiated by the thirteen vacuum pumps was putting a strain on the air-con system within the manufacturing amenities, which 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 consultants from Busch Vacuum Solutions analyzed the situation and recommended a centralized vacuum supply, which could probably be set up in a non-air-conditioned room exterior the manufacturing services.
Because Jung’s convenience merchandise have the best vacuum for packaging at a vacuum degree of four hundred millibars, Busch really helpful using MINK claw vacuum pumps. This kind 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 implies that the shifting elements contained in the vacuum pump don’t are available in contact with each other. In flip, no oil-based lubrication is required and all maintenance work associated to using 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 the three vacuum pumps is solely on stand-by. Nevertheless, the control system is programmed to make sure that all three vacuum pumps have the identical variety of operating hours.
Centralizing the vacuum supply enabled the total 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 percent discount in vitality consumption. However, in apply Jochen Neff has found that only one of the two MINK claw vacuum pumps is generally in use and that this tends to run at a lowered rotational speed. After several months of use, Jochen Neff has measured common energy consumption of 4 kilowatt hours for the whole vacuum supply. This is mainly linked to the fact that the twelve packaging strains do not all all the time run at maximum speed and not the entire machines are in use all the time. The demand-based management system then decreases the rotational speed to minimize back the output, which means that the system only offers the efficiency that is really required. In practice, this equates to power financial savings of over 90 % for vacuum technology.
The new centralized vacuum system was put in in April 2019 and has been in use every since. It is linked to the packaging machines via a community of pipelines. Two upstream vacuum vessels with a volume of 1,500 liters each ensure that the required vacuum stage is out there in the packaging chambers as soon as it’s wanted within the packaging cycle. Removing the 13 original vacuum pumps from the production areas relieved pressure from the air-con system. This meant that the air conditioning system could be turned all the means down to hold the room temperature between 5 and 6 levels Celsius. The financial savings in power costs as a outcome of lowering the air con output have not been measured. However, Picnic can generally be assumed that the change resulted in a major discount in the vitality consumed by the air conditioning system.
Thanks to the vacuum system’s redundant design, maintenance could be carried out on the person MINK claw vacuum pumps throughout manufacturing and packaging. MINK claw vacuum pumps are practically 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, dependable 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 two vacuum vessels within the background
Fig. three: Comparison of energy 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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