How Jacobs Douwe Egberts reduced energy consumption and improved production reliability

Challenge: decentralized vacuum system limits efficiency

The existing setup relied on 30 stand-alone pumps and 6 injectors operating independently across the production line. This configuration led to several challenges:

• Continuous operation regardless of actual demand
• High energy consumption and compressed air usage
• Heat generation at machine level
• Increased noise on the shop floor
• Complex maintenance across multiple units
• Difficult and time-consuming fault analysis

In case of machine failure, it was often unclear whether the issue originated from the vacuum supply, making troubleshooting inefficient.

 

 

The implementation of a centralized vacuum system with demand-driven control

Following a detailed analysis of the process, Becker implemented a centralized vacuum system capable of supplying 18 packaging machines, designed to match real production demand.

 

Beyond technical analysis, Becker provided data-driven decision support through its calculation tool. By analysing operating data and simulating different system configurations, Becker enabled clear and immediate comparison between possible solutions.

This approach ensured full transparency on energy consumption, cost efficiency, CO₂ footprint, and future scalability, allowing Jacobs Douwe Egberts to confidently identify the most suitable solution — both from a technical and economic perspective.

 

Implemented solution:

• 3 BCV 300 claw vacuum pumps with integrated VARIAIR frequency converter
  
• A centralized control cabinet equipped with a VARIAIR CONTROLLER+ monitoring interface
  

The integrated VARIAIR system allows each pump to automatically adjust its speed according to real-time vacuum demand, ensuring optimal energy efficiency.

In addition, the VARIAIR CONTROLLER+ provides full system transparency, enabling operators to monitor pump operation in real time, identify which units are running, and anticipate maintenance requirements.

The centralized system dynamically adapts vacuum generation to actual demand, ensuring efficient and stable operation at all times. This transformation also enabled the elimination of venturi systems, significantly reducing compressed air consumption.

 

Key system advantages:

• Demand-driven operation reduces energy consumption
  
• Elimination of compressed air-based venturi systems
  
• Centralized monitoring and control
  
• Real-time visibility of system performance
  
• Predictive maintenance capabilities

Becker delivered a complete turnkey solution, including system design, installation, and full system integration.

For Jacobs Douwe Egberts, this transition represents a fundamental shift in vacuum supply strategy, replacing multiple stand-alone units with a single, centralized solution fully aligned with production needs.

 

 

“Our decision to choose Becker was based on the combination of technical quality, energy efficiency, and the ability to deliver a tailor-made central solution.”

Tsjerk Hoogterp, Production Engineer Tea at Jacob Douwe Egberts

 

 

 

 

Results of the Centralized Vacuum Solution

The implementation of the centralized vacuum system has delivered immediate and measurable improvements across the entire production environment. By aligning vacuum supply with actual demand and simplifying system architecture, Jacobs Douwe Egberts achieved not only higher efficiency and reliability, but also greater operational transparency and improved working conditions.

 

Proven Energy Savings: Up to 71%
The transition from a decentralized setup to a centralized system significantly reduced energy consumption.
Annual costs decreased from €51,427 to approximately €17,034, generating savings of up to €34,394 per year — equivalent to an energy reduction of up to 71%.

 

Reliable 24/7 Operation
The centralized system ensures stable vacuum availability at all times, enabling continuous production with no downtime and consistently smooth operations.

 

High Process Reliability
Consistent vacuum levels across all connected machines improve overall process stability while enabling faster and more precise troubleshooting.

 

Significant Energy Efficiency Gains
By adapting vacuum generation to real demand and eliminating compressed air-based venturi systems, the solution significantly reduces both energy consumption and operating costs.

 

Improved Working Environment
Noise levels have been reduced by approximately 5 dB, while lower heat generation at machine level contributes to a more comfortable and productive work environment.

 

Simplified Maintenance and Faster Service
Centralizing the system streamlines maintenance activities, reduces intervention times, and makes service operations more efficient and easier to manage.

 

Full Transparency and Control
Operators benefit from complete visibility over system performance and consumption, enabling better monitoring, faster decision-making, and continuous optimization.

 

A Partnership Built on Value
Beyond the technical implementation, the project reflects a strong and long-term collaboration focused on delivering measurable results.

Becker supported Jacobs Douwe Egberts at every stage — from detailed analysis and system design to implementation and ongoing optimization — combining technical expertise with a deep understanding of the production environment.

This partnership delivers lasting value through improved efficiency, operational reliability, and continuous performance optimization.

 

Driving Performance through partnership

At Becker, partnership is built on:

• Transparent analysis and data-driven decision-making
• Tailor-made, future-proof solutions
• Long-term support and continuous improvement

With over 140 years of expertise, Becker helps manufacturers enhance performance sustainably while ensuring long-term process efficiency and reliability.

 

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