Centralised vacuum system improves efficiency in pharmaceutical pick-and-place

The challenge: continuous operation and unwanted heat within production

The first production line originally relied on eight VT 4.40 rotary vane vacuum pumps, each rated at 40 m³/h. Six were installed beneath modules along the line, with individual solenoid valves and pressure switches, while two were located on another floor. Although this arrangement provided the required vacuum, all eight pumps ran continuously, regardless of actual demand.

 

This created several operational issues:

• Unnecessary energy use from eight pumps operating 24/7
• Heat discharged into the controlled production environment
• Complex servicing across several pump locations
• Fragmented control arrangement that was difficult to optimise
• Limited visibility of how vacuum generation matched real production demand

A consultative review of the complete application

P.S.I. worked with BECKER to assess the duty point, operating pattern, pump locations, and the practical requirements of the production line. The team did not simply exchange like-for-like pumps. They considered whether centralising vacuum generation would provide a more efficient, maintainable, and resilient solution for the application itself.

 

The review identified an opportunity to move vacuum generation away from the production area and control capacity in line with demand. This would address energy, heat, and maintenance together rather than treating each issue separately.

 

 

The BECKER solution: two intelligently controlled duplex vacuum systems

The proposed design comprised two duplex packages, each using a pair of BECKER BCV 300 VAIRIAIR claw vacuum pumps. Each package was configured for duty/standby operation at 400 mbar absolute (-650 mbar gauge). Intelligent control with variable speed drive technology allows the system to respond to the production line rather than leaving every pump running continuously.

 

The packages were installed in temperature-controlled plant rooms, removing the main vacuum equipment and the heat it generates from the production environment. Centralisation also consolidated service access and replaced a scattered arrangement with a cleaner, more structured installation.

 

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THE OUTCOME: RELIABLE PERFORMANCE AND ENERGY SAVINGS ABOVE FORECAST

The centralised system was projected to reduce energy costs by €12,800 per year. After more than 12 months of operation, the installation has proved reliable, and the savings achieved during the first year exceeded the original projection. 

 

The eight initial pumps were replaced by the first centralised vacuum skid. Following its successful performance, the customer chose to install a second skid to serve another production line.

 

The manufacturer now benefits from:

• Lower energy consumption through demand-led control
• Reduced heat load in the production area
• Duty/standby resilience for production continuity
• Simpler access for planned servicing and maintenance
• A cleaner, quieter and more professional installation for customers and visitors
• A scalable central vacuum arrangement built around the application

Could you benefit from centralised vacuum generation?

Distributed pumps can be appropriate for some processes, but continuous-duty installations with several point-of-use pumps may conceal avoidable energy and maintenance costs.

 

A central system can combine capacity, introduce redundancy and match output more closely to demand. The right answer depends on the required vacuum level, flow, operating hours, pipework, controls, and production risk, so a site-specific assessment is essential.

 

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 (ETO) solutions that combine the right technology, system design and intelligent control to deliver measurable energy savings and reliable long-term performance.

 

The partnership in practice

P.S.I. - LOCAL APPLICATION PARTNER  Customer relationship, site understanding, process review, local coordination and ongoing support.

BECKER - VACUUM SYSTEM EXPERTISE Pump technology, duty-point assessment, system design support, intelligent control and engineered-to-order capability.

ONE JOINED-UP SOLUTION A practical installation designed around the process, with local service and manufacturer expertise working together.

The value of the partnership lies in combining global vacuum technology expertise with local application knowledge, responsive support, and a long-term understanding of the customer’s operation.

 

Talk to our vacuum specialists!

Where several pumps operate continuously across a production area, a structured system assessment can reveal opportunities to simplify the installation, lower energy consumption and reduce maintenance demands. Vacuum level, flow, simultaneous demand, pipework, controls and production risk must all be considered to determine the right approach.

 

Contact P.S.I. and BECKER to discuss your current vacuum arrangement and explore a solution designed around your process, priorities and plans for future growth.

 

Contact BECKER      Contact P.S.I.

 

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