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Energy efficient vacuum supply system for food packaging

2019-06-21 15:10  Times of view:

For many food manufacturers, energy efficient vacuum supply systems for food packaging are increasingly seen as the basis for economic processes. More importantly, the entire packaging process must be inspected, not just vacuum technology.

Single-chamber packaging machines, tray sealers, or thermoformed packaging machines all use vacuum technology to package fresh foods. The packaging process is hygienic and has a long shelf life. The more the company uses such a packaging machine, the longer the running time and the more power it consumes, so the operating cost of the vacuum supply system needs to be studied.

Vacuum supply system

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The vacuum pump is the heart of the vacuum supply system of the packaging machine. It is responsible for pumping out the air in the vacuum chamber and ensuring that the pre-defined packaging pressure is reached as quickly and reliably as possible before the package is sealed. Rotary vane vacuum pumps are commonly used for vacuuming vacuum chambers. For more than 50 years, relying on the R5 vacuum pump series, the Busch vacuum pump and vacuum system set the global standard for the vacuum supply of packaging machines and continue to develop and improve the standard. The latest vacuum pump R5RD debuted at the 2016 Frankfurt Meat Processing Industry Exhibition IFFA. This type of vacuum pump saves 20% in energy consumption.

For example, if a thermoformed packaging machine is equipped with the new R5RD0360A (Fig. 1), the annual electricity cost savings in a two-shift operation can reach approximately 1,500 Euros (electricity price = 0.18 EUR/kWh).

Designed for food vacuum packaging, this new R5 rotary vane vacuum pump range is easy to clean thanks to its smooth, sloping surface and automatic drain design. Its housing does not have a heat sink. All maintenance sections are installed on the operating side and only one air/oil heat exchanger needs to be replaced, thus significantly reducing maintenance. This means you can save a lot of maintenance costs.

Reduce heat load

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In general, the waste heat generated by the vacuum pump adversely affects the temperature inside the packaging machine. These waste heats can be reduced not only greatly but also utilized.

The air/oil heat exchanger of the R5 rotary vane vacuum pump can significantly reduce waste heat, thus reducing the energy cost of air conditioners. In addition, heat exchangers can be used to heat the water, which in turn can also be used during operation. The R5 rotary vane vacuum pump can be equipped with a heat exchanger.

If four packaging machines are used in one packaging room and each packaging machine is equipped with an R5 rotary vane vacuum pump with a motor power of 5.5 kW, the total cooling power required is about 6.0 kW. If the vacuum pump is operated with the heat exchanger, the required cooling power consumption can be reduced to approximately 1.5 kW. In the operating hours of 4500 hours/year, the electricity price is assumed to be 0.18 Euro/kW, which saves an annual electricity cost of about 3,700 Euros.

The use of hot water has not been taken into account in this hypothetical example.

Packaging process control

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The packaging process can be designed to be more cost effective in a number of ways: from the application of smart technology in vacuum supply, to an optimized control system, to the use of vacuum tanks. Based on the vacuum experts' field research and analysis of the customer's existing vacuum system, Busch developed several programs. Vacuum experts can point out to customers where there is potential for savings.

The goal is to develop tailor-made vacuum supply systems for customers to achieve optimal energy efficiency.

Central vacuum system

Companies that use multiple thermoforming packaging machines, tray sealers, or single-chamber packaging machines for food packaging should consider using a central vacuum system. Busch is the world's largest manufacturer of such central vacuum systems (Figure 2) with the most extensive experience. With centralized supply technology, it is usually possible to reduce energy costs by at least 50%.

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In addition, performance control can be accurately adjusted to the requirements of the overall operation. Under normal circumstances, not all packaging machines are operating under peak load conditions, so not all vacuum pumps are always running. At this point, the number of vacuum pumps required to use the central vacuum system is less than that of a distributed vacuum supply system. In addition, the central vacuum system provides maximum reliability and safety due to the redundant design of all system related components. If the vacuum pump fails or requires maintenance, the overall vacuum capacity will not be affected. The Busch central vacuum system can be fitted with a variety of different vacuum pumps. In addition to the R5 rotary vane vacuum pump, a Mink claw vacuum pump or a COBRA screw vacuum pump can also be installed as its component. Integrating existing vacuum pumps into system installations further reduces investment costs.

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