集中式真空システムが、ある玩具工場のエネルギーコストを89％削減し、6ヶ月で投資回収を実現した経緯。

3台のベッカー・クローポンプが、221台の真空エジェクタに取って代わった。

     

    Herausforderung

     

    課題
    221台の真空エジェクターは、高いエネルギー消費、過度の騒音、頻繁なメンテナンス、および不安定な真空度を引き起こしていました。

    Lösung

     

    解決策
    中央集約型のオイルフリー・ベッカー社製BCV 500 FDクロー真空システム（ポンプ3台：稼働中2台、待機1台）と、需要に応じた制御を導入しました。

    Ergebnis

     

    結果
    よりクリーンで静かな生産環境、安定したプロセス、エネルギーコスト89％削減、メンテナンス作業92.5％削減、そして6ヶ月以内の投資回収を実現しました。

     

    顧客について

    広東・香港・マカオ大湾区の主要な製造拠点にあるある玩具工場（顧客の要望により社名は非公表とする）は、典型的な設備集約型の玩具製造企業である。世界的に有名な玩具ブランドの長期サプライヤーとして、同工場では年間7,000万個以上のプラスチック製玩具を生産しています。

     

    • 工場のタイプ：設備集約型。複数の作業場に射出成形機が密集して配置されている
    • 中核プロセス：射出成形では、離型、部品の保持、位置決めのために真空が必要
    • 従来の構成：各射出成形機に専用のCONVUM製真空エジェクタが装備されていた
    • 用途：工場全体の射出成形機への真空供給
    • 課題：221台の分散型エジェクタによる真空供給

    この工場では、射出成形機に真空を供給するために221台の分散型真空エジェクタを使用していました。この構成により、いくつかの問題が発生しました：

    ⚠ 高いエネルギー消費
    221基のエジェクターが継続的に大量の圧縮空気を消費し、電気代を押し上げていた
    ⚠ 騒音公害
    手狭な作業場で221台のエジェクターが同時に稼働していたため、常に騒がしい環境となっていた
    ⚠ プロセスの不安定さ
    真空圧は圧縮空気の供給状況によって変動し、製品の品質安定性を損なっていた
    ⚠ 保守負担
    すべてのエジェクターで定期的なフィルター交換が必要であり、人件費とメンテナンスコストが大幅に増加した。
    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.

     

    Becker Claw vacuum Pump BCV 500 FD with an air flow of approx. 500 m³/h for industrial applicationsImplemented 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.

     

    Request advice from Becker ChinaFind global contacts

     

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