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How Becker Improves Energy Efficiency in Practice
Energy efficiency is no longer optional for industrial manufacturers. Rising energy prices, sustainability targets, and the need for optimized production processes have made efficient vacuum systems a strategic priority.
In many facilities, vacuum pumps operate continuously — often 24/7 — making them a significant contributor to electricity consumption. Optimizing these systems offers one of the fastest and most impactful ways to reduce operational costs and carbon emissions.
Becker supports manufacturers by combining efficient technologies with application-driven system design to deliver measurable energy savings in real industrial conditions.
Why Vacuum System Efficiency Matters
Vacuum is essential across plastics, packaging, woodworking, food processing, and environmental technology — yet many installations remain unoptimized. Common inefficiencies include fixed-speed operation regardless of demand, oversized equipment, high internal friction and wear, unnecessary heat generation, and a lack of system control. Because these systems run continuously, even small improvements can add up to substantial annual savings.
Becker’s Practical Approach to Energy Efficiency
Becker's approach is solution-oriented: deliver the required vacuum performance using the minimum necessary energy. In practice, this means designing each system around the application and combining the most relevant levers — variable speed control, dry-running technologies, right-sizing, and centralized solutions — to eliminate inefficiencies at every level.
Adapting Performance with Variable Speed Control
Running a vacuum pump at full speed at all times is one of the most common sources of energy waste.
Becker integrates variable speed drive (VSD / VARIAIR) technology to ensure that the pump output matches actual process demand.
Key Benefits
- Reduced electricity consumption
- Up to 50% energy savings depending on the application and operating conditions
- Lower operating temperatures
- Less mechanical wear
- Reduced noise levels
This approach is particularly effective in applications with fluctuating demand, such as pneumatic conveying, packaging, and CNC machining.
Improving Efficiency with Dry-Running Technology
Becker's dry-running pumps — including claw and vane technologies — maximize usable vacuum output while minimizing energy consumption. Unlike oil-lubricated systems, they operate without internal oil circulation, eliminating hidden energy losses (oil cooling/circulation, higher internal friction, filtration systems) and converting more input power directly into useful vacuum. This allows:
- Higher Energy Conversion Efficiency - With fewer internal losses, dry-running pumps convert a larger share of input energy into effective vacuum performance.
- Consistent Efficiency Over Time - Oil degradation, contamination, or improper servicing in lubricated systems can lead to progressive efficiency losses. Dry-running pumps maintain stable energy performance, even in continuous operation.
- Reduced Energy-Related Downtime and Drift - Clogged filters, worn seals, or oil-related issues often force systems to work harder to maintain performance — increasing energy consumption. Dry-running technology minimizes these risks, keeping energy use predictable.
- Lower Total Energy Footprint - Beyond direct pump consumption, dry-running systems also reduce energy linked to maintenance interventions, energy losses due to process instability, and ancillary energy (cooling, oil handling)
Focus on Claw Technology for Energy Efficiency
Becker's claw pumps are particularly efficient thanks to their contact-free operating principle — the claws never touch each other or the housing, minimizing friction losses and maintaining efficiency over the full lifecycle.
When Dry-Running Technology Maximizes Energy Savings
Dry-running technology delivers the biggest gains where systems run continuously, energy costs are a major concern, or stable vacuum levels are needed without drift. Combined with variable speed control and proper sizing, it becomes a key lever for cutting overall energy use.
Right-Sizing the System
One of the most overlooked drivers of energy consumption in vacuum systems is incorrect sizing. Systems are often oversized “to be safe”, leading to continuous overconsumption of energy far above actual process needs.
Right-sizing means selecting and configuring vacuum equipment so that it delivers the required vacuum level and flow — no more, no less.
An oversized pump uses more power than necessary, runs inefficiently at partial load, generates excess heat, and wears out faster. Right-sizing — based on accurate demand assessment, real operating profiles (not worst-case assumptions), and optimized piping/leak reduction — keeps the pump closer to its optimal efficiency point and aligns consumption with actual demand.
When combined with variable speed control, right-sizing becomes even more effective, as the system can adapt precisely to fluctuations without relying on oversized capacity.
Centralized Vacuum for Smarter Energy Use
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While individual vacuum pumps can be optimized, the highest energy efficiency gains are often achieved at system level through centralized vacuum solutions.
Instead of multiple stand-alone pumps running continuously at different machines, a centralized system supplies vacuum from a shared source, distributing it only where and when needed. |
Decentralized setups typically waste energy through pumps running when not required, oversizing at machine level, poor load distribution, and inefficient partial-load operation. Centralized systems fix this through:
- Demand-Driven Operation - Pumps only operate when needed, and at the required capacity. This avoids constant full-speed operation across multiple machines.
- Reduced Installed Power - A centralized system typically requires less total power than the sum of individual stand-alone pumps, as capacity is shared across the plant.
- Optimized Load Management - Intelligent control systems (such as Vacon+ combined with VARIAIR) ensure that pumps run at their most efficient operating point, minimizing energy losses.
- Elimination of Idle Losses - In decentralized setups, pumps often run without producing useful work. Centralization removes this inefficiency by supplying vacuum only where needed.
- Lower Ancillary Energy Consumption - Central systems reduce secondary energy needs such as cooling requirements in production areas, ventilation linked to heat generation, and compressed air usage (in case of venturi replacement)
Beyond energy savings, centralization also reduces noise, improves maintenance access, and increases process stability. It delivers the highest returns where multiple machines need vacuum simultaneously, production runs 24/7 or multi-shift, or existing systems rely on stand-alone pumps or venturi injectors.
Maintaining Performance with Preventive Maintenance
Energy efficiency does not depend only on initial system design — it also relies on consistent maintenance over time.
Regular preventive maintenance ensures that vacuum pumps operate at optimal performance levels. When components such as filters, seals, or internal parts are worn or not properly serviced, the system must work harder to deliver the same vacuum level.
Why Maintenance Matters
- Maintains optimal pump efficiency
- Prevents unnecessary energy consumption
- Reduces risk of unexpected downtime
- Extends equipment lifetime
A poorly maintained vacuum pump can lead to higher energy consumption, reduced performance, and increased operating costs. In contrast, a well-maintained system ensures stable efficiency and predictable operation.
Learn more about our preventive maintenance and service solutions to keep your vacuum systems operating at peak efficiency.
To the article about preventive maintenance and service solutions
Energy Efficiency in Practice
The real impact of these solutions becomes clear in daily operations. While results vary depending on applications and conditions, real industrial cases illustrate the potential gains.
- Food Packaging – Vacuum Sealing (Ready Meals) - A food packaging manufacturer operating 3 packaging lines was using 9 oil-lubricated vacuum pumps.
| Solution | Results |
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Centralized system with:
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Use our online calculation tool to estimate your potential energy savings in food packaging applications.
- Woodworking – CNC Machining (Crystal Doors) - A woodworking manufacturer, Crystal Doors, optimized its vacuum supply for CNC machining and vacuum workholding applications.
| Solution | Resuls |
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Centralized system with:
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Use our online calculation tool to estimate your potential energy savings in woodworking and CNC applications.
Read the full Crystal Doors case study to explore the complete project and results.
To the Crystal Doors case study
- Plastics & Rubber – CNC Machining (Carville) - A manufacturer operating multiple CNC lathes, turn-mill centers, 4- and 5-axis machining centers, and robotic cells was using an inefficient venturi-based vacuum system.
| Solution | Results |
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Replacement with a centralized Becker vacuum system:
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Energy savings: data pending
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Read the full Carville case study to explore the complete project and results.
- Secondary Packaging – Tea (Pick & Place) - A packaging facility operated by Jacobs Douwe Egberts used 30 stand-alone pumps and 6 injectors.
| Solution | Results |
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Central Becker system:
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Discover how centralized vacuum systems significantly reduced Jacobs Douwe Egberts energy consumption.
To the Jacobs Douwe Egberts case study
Supporting Sustainability Goals
Improving energy efficiency in vacuum systems directly supports sustainability goals by reducing both electricity consumption and associated CO₂ emissions.
Because these systems often run continuously, even moderate efficiency gains can lead to significant reductions in Scope 2 emissions and overall environmental footprint.
Key benefits include lower energy use with immediate CO₂ reduction, measurable KPIs for ESG reporting (kWh saved, tCO₂ avoided), support for ISO 50001 and energy management programs, and reduced secondary energy use (cooling, ventilation, compressed air). Because the savings are quantifiable, they integrate easily into corporate sustainability and energy management frameworks — and contribute directly to carbon neutrality targets and ESG reporting requirements.
By combining VARIAIR (VSD), dry-running technology, right-sizing, and centralized systems, manufacturers can reduce energy use without compromising productivity, stabilize processes while lowering environmental impact, and meet sustainability targets alongside cost savings.
Long-Term Value Beyond Energy Savings
While energy savings are often the primary driver, optimizing vacuum systems also delivers significant long-term operational value. Efficient systems run more consistently, place less stress on components, and reduce the frequency of unplanned downtime. This leads to more predictable production, improved process reliability, and fewer disruptions that can impact output and quality.
In addition, lower mechanical wear and simplified maintenance translate into extended equipment lifetime and reduced service costs. When combined with stable energy performance over time, these benefits contribute to a lower total cost of ownership (TCO) and stronger return on investment across the full lifecycle of the system.
Beyond reducing energy bills, efficient vacuum systems deliver:
- Increased operational reliability
- Lower maintenance costs
- Longer equipment lifetime
- Improved process consistency
Conclusion
Improving energy efficiency in vacuum systems is not about a single adjustment — it is the result of a holistic optimization approach. By combining variable speed control, dry-running technologies, proper system sizing, centralized architectures, and regular maintenance, manufacturers can significantly reduce energy consumption while maintaining or even improving operational performance.
The examples presented illustrate that meaningful savings are not theoretical. They are already being achieved across industries such as food, woodworking, plastics, and packaging — delivering measurable reductions in energy usage, costs, and environmental impact.
Beyond immediate savings, these improvements contribute to long-term competitiveness by lowering total cost of ownership, supporting sustainability targets, and increasing process reliability.
In today’s industrial context, optimizing vacuum systems is one of the most effective, measurable, and accessible ways to enhance both energy performance and overall operational efficiency.
Frequently Asked Questions (FAQ)
| How much energy can a vacuum pump system actually save? |
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Savings vary by application, but real-world results from Becker installations range from around 20% to as much as 71%, depending on the technology used (variable speed control, dry-running pumps, right-sizing) and how the system was previously run. The biggest gains typically come from replacing multiple stand-alone pumps with a centralized system. |
| What's the difference between dry-running and oil-lubricated vacuum pumps for energy efficiency? |
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Dry-running pumps (such as claw and vane technologies) operate without internal oil circulation, eliminating energy losses from oil cooling, filtration, and higher internal friction. This means more of the input power converts directly into usable vacuum, and efficiency stays stable over time rather than degrading as oil ages or components wear. |
| Is a centralized vacuum system always more energy-efficient than individual pumps? |
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Centralized systems generally deliver the biggest efficiency gains when multiple machines need vacuum at the same time, production runs continuously or across multiple shifts, or the existing setup relies on stand-alone pumps or venturi injectors. In these conditions, a shared system avoids the oversizing, idle running, and poor load distribution common in decentralized setups. |
| How does improving vacuum system efficiency support sustainability targets? |
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Because vacuum pumps often run continuously, even moderate efficiency improvements translate into measurable reductions in electricity use and Scope 2 CO₂ emissions. These savings are quantifiable (kWh saved, tCO₂ avoided), making them easy to incorporate into ESG reporting and energy management frameworks such as ISO 50001. |
Want to Improve Your Energy Efficiency?
Becker experts can assess your current vacuum system and identify practical opportunities to reduce energy consumption and operating costs.
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