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
221 vacuum ejectors caused high energy consumption, excessive noise, frequent maintenance and unstable vacuum levels.

SOLUTION
A central, oil-free Becker BCV 500 FD claw vacuum system (3 pumps, 2 active and 1 standby) and demand-based control.

RESULT
Cleaner, quieter production, stable processes, 89% lower energy costs, 92.5% less maintenance, and payback within six months.

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

There are three Becker claw vacuum pumps in a toy manufacturer’s production facility.

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 Annual electricity costs dropped from RMB 794,880 to RMB 89,424 — an 88.7% reduction.
✓	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.

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Author: Becker Vacuum & Air Equipment (Shanghai) Co. Ltd.