Centralised vacuum improved reliability and efficiency in aerospace machining

 

The challenge: 23 ageing pumps and limited demand diversity

Each machining centre was supported by a point-of-use pump capable of approximately 16 m³/h at 150 mbar absolute (-850 mbar gauge). Across 23 pumps, the installation provided a combined nominal capacity of 368 m³/h. However, full capacity was not required continuously. Vacuum demand fell whenever clamping, machining or lifting was not taking place, meaning the distributed system offered limited opportunity to share capacity or respond efficiently to changing production demand.

 

The existing arrangement also presented growing maintenance concerns:

 

• The pumps were entering the latter part of their service life. 
• Replacement parts were becoming more expensive and increasingly difficult to source. 
• Twenty-three separate pumps required servicing at different points across the facility. 
• Point-of-use servicing could affect machine availability. 
• A failure at an individual machining centre created a risk of interrupted production and costly material wastage. 

A consultative review of the complete vacuum system

C.S.L. worked in partnership with BECKER UK to review the application as a complete system rather than simply replacing 23 pumps on a like-for-like basis. The team assessed the required vacuum level, actual demand profile, diversity across the machining centres, service requirements, and potential for future growth opportunities. 

This application-led review identified an opportunity to centralise vacuum generation and distribute it through a purpose-designed pipework network. The proposed approach would allow installed capacity to be shared between machining centres, match pump output more closely to real demand, and build resilience into the system. 

 

The BECKER solution: intelligent central vacuum with full standby capacity

The recommended system comprised two BECKER VARIAIR BCV 300 claw vacuum pumps, coupled with an intelligent controller. The project duty was stated as 272 m³/h at 150 mbar absolute (-850 mbar gauge). Each pump incorporates an inverter, allowing output to adjust in line with actual operating conditions rather than running at a fixed level regardless of demand. Operation up to 60 Hz provides additional flexibility to meet the required duty efficiently. 

The system was arranged for 100% duty/standby operation. This means either pump can support the required duty, giving the manufacturer standby capacity if one unit requires planned maintenance or attention. 

VARIAIR BCV claw vacuum pumps use a non-contact, oil-free compression principle and integrated frequency-inverter control. For this project, the technology provided the combination of controllability, low maintenance requirements, and continuous-duty capability needed for a centralised aerospace manufacturing application. 

 

In a snapshot:
System Configuration

A new low-restriction distribution network

C.S.L. designed and installed a new smooth-bore aluminium distribution network connecting the central vacuum system to all 23 machining centres. The pipework was sized and routed to minimise restriction and support efficient flow across the facility. 

The redundant small-bore point-of-use pipework was removed, leaving a cleaner, purpose-designed network that supports both the current installation and future production requirements. 

 

The outcome: stronger resilience with fewer pumps to maintain

Following installation, Ben Hughes Engineering moved from 23 individual pumps to two centrally located, intelligently controlled vacuum pumps. The new system is more closely matched to actual usage and provides full duty/standby resilience. 

The reported operational benefits include: 

 

• Reduced power consumption by matching vacuum generation to demand 
• Substantially lower servicing requirements, with two pumps instead of 23 
• No manufacturing hours lost due to point-of-use pump servicing 
• Standby protection against interruption of the central vacuum supply 
• Reduced risk of product wastage associated with vacuum failure 
• Capacity and contingency incorporated to support future business growth 

By addressing vacuum generation, control, distribution and maintenance as one complete system, the project delivered far more than a like-for-like pump replacement. It created efficient, resilient vacuum infrastructure that meets the facility’s current requirements, provides capacity for future growth and helps keep long-term operating costs under control. 

 

Point-of-use pumps can be effective where machines operate independently or require different vacuum levels. In multi-machine facilities, however, a central system can offer meaningful advantages when demand varies between processes. Shared capacity, intelligent control and planned redundancy can reduce unnecessary running, simplify servicing and strengthen production continuity. 

The correct approach depends on the application. Vacuum level, flow, simultaneous demand, pipework pressure loss, control strategy and production risk must all be assessed before a central system is specified. 

 

After-Sales Support & Operational Outcomes

Parameter	Before	After
Maintenance	23 pumps serviced at separate locations	2 centrally located pumps to service
Spare parts and support	Parts increasingly expensive and difficult to source	Current BECKER equipment backed by manufacturer support
Production continuity	Servicing or pump failure could affect an individual machining centre	Standby protection supports uninterrupted production and planned servicing
Energy performance	Installed capacity not closely matched to actual demand	Reduced power consumption through demand-led control

 

Partnership in practice

C.S.L - LOCAL ENGINEERING PARTNER Longstanding customer relationship, site assessment, pipework design, installation and ongoing service.

BECKER - VACUUM SYSTEM EXPERTISE Pump technology, duty-point review, intelligent control and engineered-to-order capability.

ONE COMPLETE SYSTEM Generation, controls and distribution engineered together around the manufacturing process.

The customer received a complete vacuum solution, combining local engineering and installation with BECKER technology, system expertise and long-term service support.

 

Could a central vacuum system be the right solution for your application?  

This project demonstrates how C.S.L. and BECKER combine complementary expertise around the complete application. C.S.L. provides responsive local support, detailed site knowledge, pipework design, installation and ongoing service, while BECKER contributes specialist vacuum and low-pressure technology, intelligent controls and engineered-to-order system capability.

 

For manufacturers across Wales, the partnership provides a practical route from initial assessment through to installation and long-term support, backed by direct access to manufacturer expertise.

 

Where multiple point-of-use pumps operate across a production facility, a structured assessment can reveal opportunities to simplify the installation, lower energy consumption and reduce maintenance demands.

 

Contact C.S.L. and BECKER to discuss a solution designed around your process, operating conditions and plans for growth.

Frequently Asked Questions (FAQ)

 

Expert support for vacuum and low-pressure systems

BECKER’s expert team takes a consultative approach, assessing the complete vacuum or low-pressure system to understand actual process demand and identify meaningful opportunities for improvement. Where required, we develop engineered-to-order solutions that combine the right technology, system design and intelligent control to deliver measurable energy savings and reliable long-term performance. 

 

If your facility operates multiple point-of-use pumps, a structured system assessment can help establish whether centralisation could reduce energy use, simplify maintenance and improve resilience.

 

Speak to BECKER and our authorised partners about your process, operating conditions and plans for future growth. Get personal advice.

 

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