Case study: Vacuum system upgrade in a brewery - 80% less compressed air consumption thanks to FIPA components

A modern retrofit of the brewery facility using FIPA components significantly reduced energy consumption and CO₂ emissions.

The existing system for handling intermediate layers made of large cardboard sheets was modernized. By using the compact FBM mini multi-stage vacuum ejector and new TPU bellows vacuum cups from FIPA GmbH, the brewery reduced compressed air consumption by around 80% while improving process reliability.

Result: significant energy savings, lower operating costs, and a clear contribution to climate protection.

Initial situation

In the production facility of a leading German brewery, large 1.5 m x 1.5 m cardboard sheets are used as intermediate layers. The previous vacuum system consisted of one ejector and nine suction cups from a competing supplier. It showed high compressed air consumption and had room for improvement in energy efficiency and process reliability.

Vacuum system retrofit - fast and without downtime

The goal was to upgrade the existing vacuum system with a modern, energy-efficient solution without extensive mechanical modifications.

The brewery opted for the FBM mini multi-stage vacuum ejector, featuring a compact and lightweight design. The device consumes only 70 liters of compressed air per minute while offering a suction capacity of 141 liters per minute.

At the same time, TPU bellows vacuum cups were used, made from wear-resistant thermoplastic polyurethane. Thanks to their large active suction area, they ensure high suction power and excellent sealing when picking up and placing large cardboard boxes.

The entire retrofit was performed during ongoing production and was completed in a very short time - without stopping the line.

Summary

By implementing the FBM multi-stage vacuum ejector, the brewery reduced compressed air consumption by about 80%. Over 100 production days per year, this translates to annual savings of nearly €16,000.

The company also saves around 87,000 kWh of electricity annually, avoiding almost 35 tons of CO₂ emissions.

The combination of the FBM ejector and TPU bellows vacuum cups demonstrates how existing systems can be economically and sustainably optimized.

Thanks to the convincing results, the retrofit solution is now being implemented in other brewery production facilities. FIPA vacuum technology not only offers tangible cost savings but also improved process reliability in everyday operations.

Project outcome

• ✔️ Savings at all levels: 80% less compressed air, €16,000 in energy savings, 87,000 kWh less electricity and 35 tons of CO₂ per year.
• ✔️ Improved process reliability for cardboard handling.
• ✔️ Less maintenance and downtime.
• ✔️ Quick integration without major mechanical modifications.

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