The packaging of foodstuffs means many vacuum pumps in individual packaging machines are in continuous operation. This means more waste heat and more cooling required in the production halls. With a central vacuum system, you need fewer pumps, you save on cooling, and your pumps only run when vacuum is actually needed in the process. Good reasons to weigh the long-term lower energy costs against the sometimes higher initial costs.
Reduce maintenance costs: With a central vacuum system for the packaging floor, pump performance is controlled intelligently. As a result, the system is also able to react immediately to performance peaks, malfunctions or even failures. It can activate another vacuum pump and balance out the total operational performance. This reduces excessive wear and tear and keeps your pumps running in the optimal range.
It is no secret that regular maintenance work is a necessary evil. It is often associated with costs due to downtime and the employees involved. Especially if the vacuum pumps are either serviced too frequently or too infrequently.
But how do I know when maintenance really makes sense? OTTO – Digital services provides the answer. OTTO registers fluctuations or deviations in pump performance in real time and calculates the correct time for maintenance. And it gets even better: If OTTO suggests maintenance, you can send a service request to Busch technicians directly from the system.
Save on maintenance costs through digitalization and reliable service.
The vacuum pump's maximum pumping speed is not always required during the packaging process. Therefore, it should not run continuously at 100% power. Demand-driven pumps are the solution.
Thanks to their Variable Speed Drive (VSD), they precisely adapt their speed to the current process requirements and reduce your energy costs. And with our retrofit kits, you don't even have to buy a new vacuum pump. You can retrofit your current systems conveniently and cost-effectively. A Busch service technician near you will be happy to help you with your VSD update.
Up to five years of plannable costs? No problem at all with a customized Busch service contract. Save yourself additional costs due to unplanned maintenance efforts and focus on financial planning security instead. Busch technicians will take care of the maintenance and upkeep of your vacuum pumps.
With the installation of a new central vacuum system from Busch, we were able to reduce our energy requirements by more than 70%.
Packaging processes sometimes just need a little more power. After all, peaks in demand are not uncommon in the food industry. Thanks to our Variable Speed Drive (VSD), you can boost the pumping speed of your vacuum pumps by up to 20%. This ensures faster packaging cycles without the need to purchase a new vacuum pump.
Frequency control and the ability to intelligently network PLUS family pumps are just two examples of the countless advantages of a tailor-made solution from Busch. Watch the video to see all the benefits of the R5 PLUS series.
The faster, the better. This especially applies to vacuum packaging of foodstuffs. Boosters can boost the volume flow in the critical pressure range, speeding up the pump-down time. This allows the ultimate pressure and pumping speed of each vacuum pump to be increased without having to replace it with a more powerful pump. This means you can achieve higher performance by up to a factor of 10 and package your goods more quickly, making sure they remain even fresher.
In addition, a vacuum booster can be installed inside your packaging machine. Use the simple modular system for your update and request support from our service team.
Vacuum is not created at the push of a button. Instead, it builds up. The decisive factor is how quickly the necessary vacuum level is available for the packaging process. A vacuum reservoir can be used to speed up the pump-down time. All you need is a suitable vessel and professional installation by Busch.
This is because vacuum can be “buffered” during the time that the packaging machine does not need vacuum. This buffer makes the rapid pump-down time of a Busch vacuum pump for food packaging even faster.
We will be happy to assist you with the correct dimensioning of the vacuum buffer for your packaging system. From the size of the vacuum reservoir to optimal integration into your process, we are there for you. At Danish Crown Toppings, a Danish pizza topping manufacturer, Busch was able to boost efficiency enormously with the help of a buffer. Benefit now.
Do you want to take full advantage of all of the above-mentioned potentials for performance without optimizing each step individually? Then a central vacuum system is the ideal choice for you. By perfectly combining all solutions in one vacuum system, you can achieve peak power for your process.
When pumps, boosters, vacuum buffers, installation and control are precisely matched to your process requirements and work together optimally, nothing stands in the way of your productivity.
Discover the best technical solution for vacuum packaging. Let us guide you.
Sound familiar? It is a tedious task for manufacturing employees to constantly monitor oil levels and maintenance intervals.
Improve your work processes by making maintenance efforts predictable, avoiding stressful situations and minimizing potential sources of error. OTTO – Digital services gives your employees the time to concentrate on value creation and further development. Less on-call time, less overtime and fewer weekend assignments – that is how you create great working conditions.
OTTO monitors the performance of all pumps, evaluates the data and triggers an alarm before downtime becomes a problem. This means that you and your employees always have everything under control and can plan reliably. Find out more about predictive maintenance thanks to OTTO.
The quality of your foodstuffs depends on the operational reliability of your packaging process. As long as the machines are running, all food is packaged correctly and will have a longer shelf life. But as soon as there is a failure, the entire manufacturing process stops. Cheese, meat, and fish cannot be packaged and, in the worst case, can spoil. But it doesn't have to be this way. The solution is redundancy.
This is because in a central vacuum system, the power requirement is evenly distributed across all vacuum pumps, and in an emergency, one pump can quickly replace another. At the same time, the load distribution also means less wear per vacuum pump, which reduces maintenance effort. And it gets even better! Maintenance can be carried out during the week during ongoing operation thanks to the redundancy in a central vacuum system.
Learn how centralizing your vacuum supply improves your production processes.
The best packaging system is the one you don't have to worry about. Busch vacuum systems stand for outstanding reliability thanks to customized dimensions, high-quality components and excellent construction. But even the best system should be serviced regularly to maintain peak performance. Our competent Busch Service ensures this.
Secure your production output with a customized service contract and benefit from the Busch global service network. We provide fast on-site assistance and support. Around the clock. No matter where you are. Use your staff’s time and skills for tasks that bring profit and leave the maintenance to us. Busch Service is even available for maintenance work on weekends. This facilitates better personnel planning and relieves strain on your work processes.
We are extremely satisfied with our Busch IoT vacuum system. OTTO offers us absolute added value.
Almost every process has its breaks. Frequency-controlled vacuum pumps control the power of the motor during packaging, similar to the automatic start-stop system for cars. The vacuum pump or motor will only run when the power is actually needed, or will run slower when less power is needed. This means you can save up to 50% energy and protect the climate.
After all, your vacuum pumps can be easily retrofitted with Busch retrofit kits. One of our technicians will be happy to advise you on how to get the most out of your vacuum pump.
How can a central vacuum system help protect the environment? The answer is its high energy efficiency. A central vacuum system is designed to waste as little energy as possible. The less energy wasted, the fewer unnecessary emissions generated. In addition, environmentally friendly measures are sponsored by some states, which reduces investment costs.
Get a head start and prepare your system for the climate-friendly vacuum packaging of the future. With the help of a central vacuum system, you can boost your efficiency while doing something good for the environment at the same time.
The first step towards more climate change mitigation is less energy waste. The intelligent analysis by OTTO – Digital Services provides you with all the data you need to detect and prevent energy waste at an early stage. This is because the IoT system monitors the individual components in real time and indicates when filters or oil should be changed. To optimize your packaging processes and lower your energy consumption.
Digital pump documentation with OTTO is also extremely helpful for audits and certifications. Especially for the food industry, it is very easy to export relevant key figures for the IFS7 audit.
With the new central vacuum system from Busch, we installed the latest in vacuum technology.
Vacuum packaging is the technique of removing air from a package containing a product, usually food, before it is sealed. The air and thus the oxygen are extracted, and the product is preserved.
The product to be packaged is placed in a bag, on a tray or between two airtight foils. Inside a vacuum chamber or a sealing station, this package is then evacuated by means of a vacuum pump. After reaching the respective target vacuum, the package is sealed. For certain products, a specifically defined gas mixture is introduced into the packaging prior to sealing. This is called modified atmosphere packaging (MAP).
Vacuum frequently plays an essential role in packaging processes. In the manufacturing of packaging, vacuum is, for example, used for thermoforming. Vacuum is also employed in tray sealing, chamber packaging, thermoforming and bag filling packaging machines and in many other packaging applications. Furthermore, vacuum is used for pick-and-place applications during the packaging process, as well as for handling packages.
Busch is the market leader in vacuum technology for food packaging. With more than 3 million R5 rotary vane vacuum pumps delivered into the vacuum packaging market worldwide. Our solutions are present in most chamber packaging machines, thermoforming packaging machines, tray sealing machines and bag filling machines throughout the world.
Vacuum helps to keep food fresh for a long time. With no loss in quality. Depending on the type of food to be packaged as well as the corresponding requirements, there are several possible processes. These include chamber packaging, thermoforming packaging, clipped packaging and carousel packaging.
Every vacuum packaging process starts with placing the products into some type of packaging. Either inside a bag, between an upper and a lower foil, or into a tray. The air, and thus the oxygen, is then evacuated from the packaging before it is sealed. This ensures an extended shelf life for the packaged product due to a reduced growth of oxygen-dependent bacteria. Furthermore, the taste, smell and appearance of the packaged products are preserved. And drying of the foodstuffs as a result of evaporation is reduced.
Vacuum packaging of fresh foodstuffs allows a reduction of oxygen in the package by around a factor of 200. This makes it possible to maintain the quality, appearance, freshness, and flavor of the packaged product. The growth of aerobic bacteria and thus oxidation and degradation of the product are prevented. This, in turn, helps to drastically reduce global food waste.
In addition, vacuum packaging allows for attractive product presentation for the customer, especially of convenience food, at the point of sale.
For certain products, a special gas mixture is introduced into the package before it is finally sealed. This technique is called modified atmosphere packaging (MAP).
Vacuum packaging is not limited to solids. Liquids such as oil, sauces, remoulades or dressings can also be packaged under vacuum.
Packaging these goods presents special challenges. In order to prevent the liquids leaking during the packaging process, the bags are positioned vertically or inclined inside the vacuum chamber. Moreover, liquids and wet products carry the risk of boiling during vacuuming. This needs to be prevented in order to avoid damage to the product.
Vacuum packaging plays an important role in medical environments where a high level of hygiene is indispensable. Medical equipment packaged under vacuum is kept safe from accidental spills or splatters and other potential sources of contamination. Vacuum packaging thus helps to keep medical devices, surgical tools and personal protective equipment sterile.
It also effectively protects items from other environmental influences such as humidity and can, for example, help to prevent condensation during storage.
Vacuum packaging is also a quick and space-saving method of packaging. This makes it ideal for hospital use, where items like bedding and clothing need to be stored in a compact manner.
Vacuum can be used for thermoforming of plastic cavities or pockets for blister packaging. The packaging is usually sealed with cardboard, a lidding seal made of aluminum foil, or a printed plastic film that allows product information or branding to be displayed.
Blister packaging has the advantage of exhibiting a product while simultaneously avoiding contact with external factors such as humidity and contamination. Moreover, tampering with the packaged items can be prevented. If opaque blisters are used, the packaged product can also be protected against UV rays.
Blister packs are often used as unit-dose packaging for pharmaceuticals like tablets or capsules, but also for small consumer goods or foodstuffs.
Vacuum packaging is the most effective and reliable method of storing currency.
Bundles of a predefined quantity of banknotes are vacuumized. The plastic packaging can then be printed with the bank or branch's seal and a specific identity code. This makes the transport and storage of the packages traceable and safe. Theft and fraud can be prevented because a manipulated package is easily recognizable by a broken seal and an increase in air inside the plastic bag.
Vacuum packaged banknotes can be stored in a very compact way as the air is extracted and the volume of the package is thus reduced to a minimum. The packages therefore need less space and can be transported easily.
Moreover, vacuum packaging allows currencies to be protected from harmful external influences like moisture or dirt.
Vacuum packaging is a cost-effective and economical way of protecting goods – both hygienically and mechanically. The air, and thus the oxygen, are evacuated from the packaging prior to it being sealed. This offers the advantage of protecting the packaged goods against the growth of oxygen-dependent bacteria, which is especially important when it comes to packaging foodstuffs. Product dehydration is also greatly reduced. Due to the limited contact with oxygen, vacuum-packaged foodstuffs keep their quality, taste, smell, and appearance for a long time, extending their shelf-life.
Rotary vane vacuum pumps are the first choice for vacuum packaging. Dry screw vacuum pumps, vacuum boosters, liquid ring vacuum pumps, claw vacuum pumps and rotary lobe blowers also have specific roles in packaging. Each of them offers its own distinct advantage depending on the specific application.
The most suitable vacuum generators for packaging are R5 rotary vane vacuum pumps, COBRA dry screw vacuum pumps, PANDA/PUMA vacuum boosters, MINK dry claw vacuum pumps and DOLPHIN liquid ring vacuum pumps. The choice of the optimal product depends on the specific process requirements. But also on the customer's priorities.
Cycle time, chamber size, pump-down time, operating time, reliability, warm-up time and availability – these factors are crucial when deciding which packaging machine to purchase. Also worth noting are the manpower required, energy and oil consumption, maintenance, and overhaul costs, and floor space.
However, there is no one-size-fits-all vacuum packaging solution. For the purpose of designing the best solution for your needs, more general factors can also be taken into consideration:
Peace of mind
The best vacuum system is the one you never have to worry about. It should deliver the required performance. And run seamlessly and reliably. This is achieved by choosing the vacuum pump best suited to the application in question and the specific requirements.
To extend the lifetime of a vacuum system, several factors should be considered. For example, the use of the right technology and the right pump configuration. Another consideration is the proper use of the system. Following the operating instructions and carrying out regular maintenance is recommended.
Saving money with a system upgrade
Your processes, including the vacuum demand, may have changed. This leads to the following questions: Is the system still in line with your needs? Is it still operating as energy-efficiently as possible? When it is time to upgrade or replace a vacuum system, it is worth looking at the entire installation. With an expert, try to identify any potential for optimization. Modern technologies can increase productivity and save money by reducing operating costs and energy consumption.
A central vacuum supply offers the potential to reduce operating costs and to increase energy efficiency.
Central vacuum systems from Busch are in operation throughout the world. In food packaging but also in many other industries.
We offer turnkey solutions tailored to individual process requirements. Including pipework and control installation, together with start-up service and training for the operating team.
Are you looking for a central vacuum system to optimize your packaging process?