FIPA retrofit significantly reduces operating costs and CO2 emissions

Brewery saves 80% compressed air in intermediate layer handling of large cardboard boxes

Initial situation

In a production plant of a leading German brewery, large cardboard boxes in the format 1.5 m x 1.5 m are processed as intermediate layers.
The previous vacuum system consisted of an ejector and nine vacuum cups from a competitor. This system was very compressed air-intensive and offered potential for improvement in terms of energy efficiency and process reliability.

Solution approach

The brewery’s aim was to retrofit the existing system with a modern, energy-efficient vacuum system – without extensive mechanical modifications.
The choice fell on the FBM mini multi-stage vacuum ejector in a compact, lightweight design, which only requires 70 litres of compressed air per minute with a suction capacity of 141 litres per minute.
At the same time, new round bellows vacuum cups made of TPU, a wear-resistant, thermoplastic polyurethane, were used, which ensure high suction power and good sealing when sucking in and setting down the large cardboard boxes thanks to their large active suction surface.
The conversion was carried out during operation and was completed in a very short time.

Conclusion

By using the FBM mini multi-stage vacuum ejector, the brewery was able to reduce its compressed air consumption by around 80 percent. With 100 production days per year, this means annual cost savings of just under 16,000 euros. In addition, the company saves around 87,000 kWh of electricity, thereby avoiding around 35 tons of CO₂. The result: significant energy savings, lower costs and an important contribution to climate protection.

The use of the FBM mini multi-stage vacuum ejector in combination with the TPU bellows vacuum cups impressively demonstrates how existing systems can be optimized economically and sustainably.
Due to the convincing results, the retrofit solution is now being rolled out at other production sites of the brewery.
FIPA vacuum technology thus not only offers noticeable cost savings, but also greater process reliability in day-to-day operations.

Result

Savings at all levels:
80% less compressed air, €16,000 in energy costs, 87,000 kWh of electricity and 35 tons of CO₂ per year
Improved process reliability for cardboard handling
Less maintenance required
Quick integration without major conversions

< See all news