Vacuum pump for inline thermoformers

The heart of primary food packaging

Inline thermoformers are the functional center of modern packaging processes. They combine high cycle rates, precise forming, filling, and sealing, and enable cost-effective processes in sensitive hygiene environments.

Typical applications are:

Meat & sausage products
Cheese products
Fish & seafood
Ready meals & convenience foods
Vegan & vegetarian products
Baked goods & delicatessen

An inline thermoformer combines several
process steps in a single line:

Film removal
Deep drawing of the bottom film using vacuum
Product handling
Evacuation and, if necessary, protective gas flushing (MAP)
Sealing
Cutting & dispensing

Inline thermoformer

The result: With an inline thermoformer, thousands of packaging units per hour can be produced with the highest standards of repeat accuracy, stability, and hygiene.

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The role of vacuum technology in the thermoforming process

Inline thermoformers require several precisely controlled vacuum levels:

Pumps

Thermoforming vacuum (vacuum forming)

shapes the bottom film cleanly into the mold – depends on film thickness, material, and temperature

Pumps for process vacuum

Process vacuum for evacuation

determines the residual oxygen values – particularly critical for meat, cheese, and MAP

Support and control pressure zones inline thermoformer

Control and support pressure zones

enable fast, repetitive movements – important for high cycle rates in inline operation

To ensure that these processes run smoothly, the thermoformer needs a vacuum solution that responds quickly, remains pressure-stable, operates energy-efficiently and at the same time withstands the challenging conditions of food production, such as moisture, cleaning processes and temperature differences.

Why operators are looking for new, low-maintenance alternatives

Many existing systems still use oil-lubricated rotary vane pumps. However, the advantages in deep evacuation are offset by challenges:

Wear due to vane contact
Comparable frequent filter changes
Oil-dependent performance (e.g., viscosity at cold room temperatures)
Unplanned stops due to vane breakage or oil problems
Service costs

OEMs are now specifically asking for low-maintenance solutions, especially in the area of forming vacuum and process vacuum for fast cycles. Thanks to its extensive product portfolio, Becker offers exactly the right solution: reliable, low-maintenance, and energy-efficient.

U5 rotary vane pumps:
Reliable high vacuum for process-stable and reproducible thermoformed packaging

The oil-lubricated rotary vane technology of the Becker U5 series (U 5.65/101/166/201/301) enables stable, fast and reproducible packaging processes, as it is robust against moisture and process gases and also offers excellent cost-effectiveness over its entire lifecycle. They are the ideal choice for low-vacuum applications (evacuation) in inline thermoforming machines:

Low final pressures for deep vacuum
Process-stable performance even in continuous operation
Good tolerance to steam and particles
Energy efficiency in demanding applications
Long service life despite humid packaging environments
The O2-PACK versions of the U 5.101-301 vacuum pumps are ideal for evacuation and MAP phases in primary packaging facilities.

RBP Roots booster pumps:
Maximum evacuation rate for high-performance inline thermoformer

The Roots booster technology of the Becker RBP series (RBP 500/1000/2000), when used in conjunction with an oil-lubricated rotary vane vacuum pump as a fore-pump, delivers maximum evacuation performance. – High cycle rates and the necessary process robustness are ensured. These systems offer the best combination of performance, robustness and cost-effectiveness. Consequently, they are the industry standard for high-performance thermoforming packaging solutions:

Extremely rapid pressure reduction
Shorter cycle times
Consistent vacuum level across the process zones
High suction capacity in the medium pressure range
Optimisation of large thermoforming lines
Large in-line thermoformers in particular benefit greatly from the combination of a backing pump and a booster.

BCV claw pumps:
Low-maintenance, high-performance vacuum technology for high cycle rates and maximum system uptime

The contact-free claw technology of the Becker BCV series (BCV 100/150/300/400/500) addresses the core requirements of modern inline thermoformers:

Non-contact compression:
no wear in the compression chamber, no vane replacement, and no oil-related fluctuations
High suction capacity for fast pressure reduction:
ideal for high cycle rates and reduced forming and evacuation times
Increased system availability:
fewer service calls and longer uninterrupted running times
Energy-efficient continuous operation:
optimised efficiency and significant savings potential for 24/7 production
Resistant to moisture and cleaning cycles:
ideal for cold rooms and high-hygiene zones

More information:

Filter concept: fewer cleanings, fewer stops

The BCV series offers a sophisticated filtration system:

Integrated filter with transparent cover
Visual inspection without opening
Prevents unplanned stops
Enlarged filter surface
Longer cleaning intervals
Fewer interventions in the running line

Filter detail vacuum pump BCV 500

This makes Becker BCV claw pumps particularly suitable for use in inline thermoformers.

Calculation example: Energy savings in continuous operation

An operator-relevant example for
typical inline thermoformers

Initial situation:
Oil-lubricated rotary vane pump, 4 kW, 24/7 operation

BCV equivalent:
BCV 300 (claw pump), 2.9 kW power consumption

Savings per pump

Annual consumption:

Rotary vane: 4.0 kW × 8,760 h = 35,040 kWh
BCV 300: 2.9 kW × 8,760 h = 25,404 kWh
Difference: 35,040 kWh - 25,404 kWh = 9,636 kWh/year

Annual cost savings:

9,636 kWh × 0.20 € = 1,927 € per year per pump

Cost savings from a central vacuum system in the food industry

In the same operating scenario, the Becker BCV 300 vane pump requires only 2.9 kW instead of 4.0 kW, thereby saving 9,636 kWh or approximately €1,927 per pump per year (based on €0.20/kWh and 8,760 operating hours).*

For a line with 2–3 pumps, savings of 5,000 € per year are realistic – without even factoring in the maintenance benefits.

With reduced maintenance costs (vanes, oil, service calls), ROI times of less than 12 months are absolutely common.

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Typical thermoforming scenarios for the BCV series

High-performance machines for meat & cheese
MAP packaging lines
Systems with high demand utilisation
Thermoformers in refrigerated areas
Retrofit projects for problem pumps
Systems with demanding hygiene and cleaning cycles

Conclusion

The BCV series is the new benchmark for low-maintenance thermoformers

BCV claw pumps combine:

✓	Fast pressure reduction for high cycle rates
✓	Stable vacuum levels for consistent packaging quality
✓	Maintenance-free compression system

✓	Long filter intervals
✓	High energy efficiency
✓	Robustness in demanding production areas

Becker BCV claw pumps are the ideal solution for OEM designs and retrofit projects on in-line thermoformers, where maximum uptime and minimal maintenance are crucial.

In addition, oil-lubricated rotary vane vacuum pumps from the U5 series are frequently used in inline thermoforming machines. They are a tried-and-tested solution for applications requiring a high, constant ultimate vacuum and are characterised by their reliability and process stability.

For particularly high suction flow rates or short evacuation times, the packaging systems can be modularly expanded with RBP Roots boosters. In combination with U5 vacuum pumps, they enable a significant increase in performance: ideal for high-performance inline thermoformers with high throughput.

Contact us today for a individual quote – or find out more in our overview of solutions for the food industry.

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