How a Centralized Vacuum System Helped a Toy Factory Cut Energy Costs by 89% with a 6-Month Payback.
3 Becker Claw Pumps Replaced 221 Vacuum Ejectors.
|
CHALLENGE |
SOLUTION |
RESULT |
About the Customer
A toy factory in the core manufacturing hub of the Guangdong – Hong Kong – Macao Greater Bay Area – whose name we're keeping confidential at the customer's request – is a typical equipment-intensive toy manufacturing enterprise. As a long-term supplier to globally renowned toy brands, the factory produces more than 70 million plastic toys annually.
- Plant type: Equipment-intensive, with injection molding machines densely arranged across multiple workshops
- Core process: Injection molding requires vacuum for demolding, part holding, and positioning
- Original setup: Each injection molding machine was equipped with a dedicated CONVUM vacuum ejector
- Application: Vacuum supply for injection molding machines across the entire plant
- Challenge: Vacuum Supply with 221 Decentralised Ejectors
The factory used 221 decentralised vacuum ejectors to provide vacuum for their injection molding machines. This setup caused several issues:
| ⚠ | High energy consumption 221 ejectors continuously consumed large volumes of compressed air, driving up electricity costs |
|
| ⚠ | Noise pollution 221 ejectors operating simultaneously in a densely packed workshop contributed to a persistently noisy environment |
|
| ⚠ | Process instability Vacuum pressure fluctuated with compressed air supply, compromising product consistency |
|
| ⚠ | Maintenance burden Every ejector required regular filter replacement, adding significant labor overhead and maintenance cost. |
| Parameter | Value |
| Total vacuum ejectors installed | 221 units |
| Air consumption per CV-10HS | 45 L/min (compressed air) |
| Air consumption per CV-15HS | 105 L/min (compressed air) |
| Total compressed air consumption | Approx. 973 m³/h (measured on site) |
| Conversion factor | 1 kW electricity ≈ 6 m³ compressed air |
| Annual electricity consumption | Approx. 1,152,000 kWh |
| Electricity rate | RMB 0.69/kWh |
| Annual electricity cost | Approx. RMB 794,880 |
| Estimated annual maintenance cost | Approx. RMB 100,000 |
Combined annual cost: nearly RMB 900,000
These problems created process risks and operational cost increasing for a high-volume manufacturer supplying globally recognised toy brands.
Smoothly Integrated: one central, oil-free Becker BCV 500 FD claw system
Becker analysed the real vacuum and flow requirements on site, checked for leaks and evaluated power usage and load peaks. The analysis showed that one central, dry-running claw vacuum system provides stable performance with significantly lower overall operating costs.
Implemented solution:
- 3× Becker BCV 500 FD claw vacuum pumps (2 active + 1 standby), rated at 460 m³/h each at -70 kPa
- Central vacuum distribution system with piping to all injection molding machines
- Demand-based control for optimal energy efficiency
- Compact FD design saving valuable floor space
Why the BCV 500 FD Claw Pump?
Becker’s claw vacuum pumps are built on three core principles that set them apart from conventional vacuum technologies:
| ✓ |
100% oil-free operation Becker claw vacuum pumps compress 100% oil-free and operate without contact. The dry-running claw mechanism eliminates the risk of oil contamination in your production environment and avoids the cost and hassle of oil disposal. |
| ✓ |
Minimal maintenance The non-contact operating principle means there is no internal friction and no wear between the rotors. Combined with integrated filtration and air-cooling, this makes the pump particularly low-maintenance, reducing operating costs and the need for serviceable parts while maximising efficiency and productivity. |
| ✓ |
High energy efficiency Thanks to their low installed motor power, Becker‘s energy-efficient claw vacuum pumps are also very cost-effective to run. The precise claw design delivers high efficiency with low energy consumption, keeping operating costs to a minimum. |
The BCV 500 FD runs completely oil-free
The vacuum pump is built for continuous operation and needs very little maintenance. The transparent filter cover also makes the inlet filter quick and easy to check.
Results of the Switchover to Becker Vacuum Technology
By using the Becker BCV 500 FD claw vacuum system, the following results were achieved for the toy factory:
| ✓ |
Lower energy bill |
| ✓ |
Cleaner, quieter production environment No oil mist, no oil changes, and noise levels reduced from over 90 dB to below 75 dB. |
| ✓ |
Fewer production stops Centralized system delivers consistent pressure, directly improving product yield. |
| ✓ |
Lower maintenance effort No oil and virtually maintenance-free operation. Annual maintenance costs were reduced to RMB 7,500, which is 92.5% lower than before. |
| ✓ |
Easier operation Simpler monitoring and more predictable maintenance planning |
| ✓ |
Reduced risk of unexpected downtime 2 active and 1 standby configuration ensures no downtime during routine maintenance. |
| Parameter | Before | After |
| Number of equipment | 221 Ejectors | 3 BCV 500 FD Claw Vacuum Pumps |
| Annual electricity cost | RMB 794,880 | RMB 89,424 |
| Annual maintenance cost | RMB 100,000 | RMB 7,500 |
| Total annual operating cost | RMB 894,880 | RMB 96,924 |
| Noise level | >90 dB | <75 dB |
Annual savings: approximately RMB 798,000 — full payback within six months.
Frequently Asked Questions (FAQ)
| Which Becker pump does the toy factory use? |
|
The factory installed a central, dry-running claw vacuum system with 3× BCV 500 FD pumps (2 active + 1 standby), rated at 460 m³/h each at -70 kPa, including a central vacuum distribution system with piping to all injection molding machines. |
| In which applications is the BCV500 FD used? |
|
The pumps are used for vacuum supply to injection molding machines across the entire plant, specifically for demolding, part holding and positioning in plastic toy component production. |
| How did the Becker solution solve the problem? |
|
With a central, oil-free vacuum supply including demand-based control. This ensures stable vacuum levels, far less maintenance, a quieter production environment and fewer production interruptions — all while reducing energy costs by nearly 90%. |
| Why did the customer choose Becker? |
|
The customer chose Becker because the BCV 500 FD claw pump offers oil-free technology, reliable vacuum performance for injection molding, minimal maintenance and an energy-saving central vacuum setup — with a payback period of under six months. |
| How does the BCV 500 FD compare to the previous ejector setup? |
|
The BCV 500 FD runs completely oil-free, almost maintenance free, requires only periodic clearance checks, operates at below 75dB, and delivers stable vacuum independent of compressed air fluctuations — eliminating the high energy costs, noise and maintenance burden of 221 decentralised ejectors. |
Customized Vacuum Solutions
Every manufacturing plant has unique operating conditions, budgets, and priorities. Whether your priority is the lowest long-term operating cost, a balanced approach between upfront investment and running expenses, or the best cost-performance ratio with the fastest payback, we can design a central vacuum system that best fits your specific needs.
3 pumps replacing 221 vacuum ejectors. RMB 800,000 saved annually. Payback in six months. These are not just numbers — they represent the tangible value we deliver to our customers.
If your facility is also considering a vacuum system upgrade, we invite you to reach out for a complimentary on-site assessment and a customized retrofit proposal.
Ready to optimize your vacuum supply? Contact Becker China for a complimentary on-site assessment and customized proposal.
Request advice from Becker ChinaFind global contacts
Author: Becker Vacuum & Air Equipment (Shanghai) Co. Ltd.
Follow us: